Front Timing Chain Case: Removal and Installation
Front Timing Chain Case: Removal and InstallationNOTE:
^ This information describes removal /installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle.
^ When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and installation is in the reverse order of removal.
REMOVAL
1) Remove engine room cover using power tool.
2) Release the fuel pressure.
3) Drain engine oil.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine oil on drive belts.
4) Drain engine coolant from radiator.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
5) Remove radiator cooling fan assembly.
6) Separate engine harnesses removing their brackets from front timing chain case.
7) Remove drive belts.
8) Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
9) Remove power steering oil pump bracket.
10) Remove generator.
11) Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
12) Remove right and left intake valve timing control covers.
^ Loosen bolts in reverse order as shown.
^ Cut liquid gasket for removal using Tool.
Tool number KV10111100 (J-37228)
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
13) Remove collared O-rings from front timing chain case (left and right side).
14) Remove rocker covers (right and left banks).
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
15) Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE:
When timing chain is not removed/installed, this step is not required.
a) Rotate crankshaft pulley clockwise to align timing mark (A) (grooved line without color) with timing indicator (B).
b) Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown.
^ If not, turn crankshaft one revolution (360 degrees) and align as shown.
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets.
16) Remove crankshaft pulley as follows:
a) Remove starter motor and set Tool.
Tool number (J-48761)
b) Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position.
CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect the crankshaft pulley from dropping.
c) Pull crankshaft pulley with both hands to remove it.
17) Loosen two bolts in front of oil pan (upper) in reverse order as shown.
18) Remove front timing chain case as follows:
a) Loosen bolts with power tool in reverse order as shown.
b) Insert suitable tool into the notch at the top of the front timing chain case as shown (1).
c) Pry off case by moving tool as shown (2).
^ Cut liquid gasket for removal using Tool.
Tool number: KV10111100 (J- 37228)
CAUTION:
^ Do not use screwdriver or something similar.
^ After removal, handle front timing chain case carefully so it does not twist, bend, or warp under a load.
19) Remove O-rings from rear timing chain case.
20) Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
^ Cut liquid gasket for removal using Tool.
Tool number: KV10111100 (J-37228)
21) Remove front oil seal from front timing chain case using suitable tool.
CAUTION:
Be careful not to damage front timing chain case.
22) Remove timing chain and related parts.
23) Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces.
CAUTION:
Be careful not to allow gasket fragments to enter oil pan.
^ Remove old liquid gasket from bolt hole and thread.
24) Use a scraper to remove all traces of old liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
INSTALLATION
1) Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
2) Install new front oil seal on the front timing chain case.
^ Apply new engine oil to both oil seal lip and dust seal lip.
^ Install it so that each seal lip is oriented as shown.
^ Press-fit oil seal until it becomes flush with front timing chain case end face using suitable drift [outer diameter: 60 mm (2.36 in)].
^ Make sure the garter spring is in position and seal lip is not inverted.
3) Install water pump cover and chain tensioner cover to front timing chain case, if removed.
^ Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown.
Tool number: WS39930000 ( - )
Use Genuine RTV Silicone Sealant or equivalent.
4) Install front timing chain case as follows:
a) Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.
Use Genuine RTV Silicone Sealant or equivalent.
b) Install new O-rings on rear timing chain case.
c) Assemble front timing chain case as follows:
i) Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely.
ii) Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily while holding front timing chain case from front and top as shown.
iii) Same as the previous step, insert dowel pin while holding front timing chain case from front and top completely.
d) Tighten bolts to the specified torque in numerical order as shown.
e) After all bolts are tightened, retighten them to the specified torque in numerical order as shown.
^ There are four type of bolts.
Bolt position Bolt diameter
1-5 :10 mm (0.39 in)
6-25 :6 mm (0.24 in)
Bolt position Tightening specification
1-5 :55.0 Nm (5.6 kg-m, 41 ft-lb)
6-25 :12.7 Nm (1.3 kg-m, 9 ft-lb)
5) Install two bolts in front of oil pan (upper) in numerical order as shown.
Front oil pan bolt torque :22.0 Nm (2.2 kg-m, 16 ft-lb)
6) Install right and left intake valve timing control covers as follows:
a) Install new seal rings in shaft grooves.
b) Apply a continuous bead of liquid gasket using Tool to intake valve timing control covers as shown.
Use Genuine RTV Silicone Sealant or equivalent.
Tool number: WS39930000 ( - )
c) Install new collared O-rings in front timing chain case oil hole (left and right sides).
d) Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers.
e) Tighten bolts in numerical order as shown.
7) Install crankshaft pulley as follows:
a) Install crankshaft pulley, taking care not to damage front oil seal.
^ When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
b) Tighten crankshaft pulley bolt in two steps.
Step 1 :44.1 Nm (4.5 kg-m, 33 ft-lb)
Step 2 :84 degrees - 90 degrees clockwise
c) Remove Tool.
Tool number :- (J-48761)
8) Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
9) Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
^ Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the connection points.
^ Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.
^ Summary of the inspection items:
