Timing Chain: Service and Repair

CHAIN SUB-ASSEMBLY
REPLACEMENT

HINT: Refer to CAMSHAFT (RH BANK) or CAMSHAFT (LH BANK) for the replacement procedure of the No.2 chain.

1. REMOVE POWER STEERING LINK ASSEMBLY
2. REMOVE DIFFERENTIAL CARRIER ASSEMBLY FRONT (4WD DRIVE TYPE)
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE BATTERY
6. REMOVE V-BANK COVER
7. REMOVE RADIATOR SUPPORT SEAL UPPER
a. Remove the 11 clips and radiator support seal upper.
8. LOOSEN FAN W/ FLUID COUPLING
9. REMOVE FAN AND GENERATOR V BELT
10. REMOVE FAN W/ FLUID COUPLING
11. DISCONNECT VENTILATION HOSE NO.2
12. REMOVE AIR CLEANER ASSEMBLY
13. REMOVE OIL LEVEL GAUGE GUIDE
a. Remove the oil level gauge.
b. Remove the bolt and pull out the oil level gauge guide.
c. Remove the O-ring from the oil level gauge guide.
14. REMOVE WATER INLET





15. SEPARATE VANE PUMP ASSEMBLY
a. Disconnect the P/S oil pressure switch connector.
b. Remove the 2 bolts, and separate the vane pump.

NOTICE: Do not hit the pulley to other parts when separating the vane pump.

HINT: The vane pump is suspended securely.

16. REMOVE GENERATOR ASSEMBLY
17. SEPARATE COOLER COMPRESSOR ASSEMBLY





18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the 5 bolts and V-ribbed belt tensioner.
19. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and 2 idler pulleys.
20. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
a. Remove the bolt and idler pulley.
21. REMOVE CRANKSHAFT PULLEY





a. Using SST, hold the crankshaft pulley and loosen the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021





b. Using the pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05030)
22. REMOVE OIL PAN SUB-ASSEMBLY NO.2





a. Remove the 10 bolts and 2 nuts.





b. Insert the blade of SST between the oil pan and oil pan No.2, cut off applied sealer and remove the oil pan No.2.
SST 09032-00100

NOTICE:
^ Be careful not to damage the contact surfaces of the oil pan and oil pan No.2.
^ Be careful not to damage the oil pan No.2 flange.





23. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the 2 nuts, oil strainer and gasket.
24. REMOVE OIL PAN SUB-ASSEMBLY





a. Remove the 4 housing bolts.
b. Remove the flywheel housing under cover.





c. Remove the 17 bolts and 2 nuts.





d. Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block as shown in the illustration.

NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pan.

e. Remove the O-ring from the oil pump.
25. REMOVE INTAKE AIR SURGE TANK
26. REMOVE IGNITION COIL ASSEMBLY
27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
29. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Disconnect the 2 oil control valve connectors.
b. Remove the 2 bolts and 2 camshaft timing oil control valves.
30. REMOVE VVT SENSOR
31. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
32. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
33. SET NO. 1 CYLINDER TO TDC/COMPRESSION





a. Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.





b. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.
If not, turn the crankshaft 1 complete revolution (360°) and align the timing marks as above.





34. REMOVE CHAIN TENSIONER ASSEMBLY NO.1

NOTICE:
^ Never rotate the crankshaft with the chain tensioner removed.
^ When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

a. While turning the stopper plate of the tensioner clockwise, push in the plunger of the chain tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 inch) into the holes on the stopper plate and tensioner to fix the stopper plate.
c. Remove the 2 bolts and chain tensioner.
35. REMOVE CHAIN TENSIONER SLIPPER





36. REMOVE IDLE GEAR NO.1
a. Using a 10 mm hexagon wrench, remove the idle gear shaft No.2, idle gear No.1 and idle gear shaft No.1.
37. REMOVE CHAIN VIBRATION DAMPER NO.2
a. Remove the 2 chain vibration damper No.2.
38. REMOVE CHAIN SUB-ASSEMBLY
39. INSTALL CHAIN TENSIONER SLIPPER





40. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 inch) into the holes on the stopper plate and tensioner to fix the stopper plate.
c. Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





41. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No.1 cylinder to the TDC/ compression.
1 Align the timing marks of the camshaft timing gears and bearing caps.





2 Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.





b. Align the mark link (yellow) with the timing mark of the crankshaft timing gear.





c. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
42. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Instal the 2 chain vibration damper No.2.
43. INSTALL IDLE GEAR NO.1
a. Apply a light coat of engine oil to the rotating surface of the idle gear shaft No.1.





b. Temporarily install the idle gear shaft No.1 and idle gear No. 1 with the idle gear shaft No.2 while aligning the knock pin of the idle gear shaft No.1 with the knock pin groove of the cylinder block.

NOTICE: Be careful of the idle gear direction.

c. Using a 10 mm hexagon wrench, tighten the idle gear shaft No.2.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
d. Remove the bar from the chain tensioner.
44. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09226-10010
45. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
46. INSTALL VVT SENSOR
47. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
48. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
50. INSTALL IGNITION COIL ASSEMBLY
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
51. INSTALL INTAKE AIR SURGE TANK
52. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.





b. Install a new O-ring to the oil pump.





c. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 inch)) to the oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.





d. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt B
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt C
21 Nm (214 kgf-cm, 15 ft. lbs.) for nut

HINT: Each bolt length is as follows:
A 25 mm (0.98 inch)
B 45 mm (1.77inch)
C 14 mm (0.55 inch)





e. Install the 4 housing bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
f. Install the flywheel housing under cover.





53. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
54. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No.2.





b. Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Install the oil pan No.2 within 3 minutes after applying seal packing. After installing it, the oil pan No.2 bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.





c. Install the oil pan No.2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





55. INSTALL CRANKSHAFT PULLEY
a. Using SST, install the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft. lbs.)





56. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
a. Install the idler pulley with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

HINT: "DOUBLE" is marked on the idler pulley No.1 to distinguish it from the idler pulley No.2.





57. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the 2 idler pulleys with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)





58. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
b. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
c. Tighten the other bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)

HINT: Each bolt length is as follows:
A 70 mm (2.76 inch)
B 33 mm (1.30 inch)

59. INSTALL COOLER COMPRESSOR ASSEMBLY
60. INSTALL GENERATOR ASSEMBLY





61. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

NOTICE: Do not hit the pulley to other parts when installing the vane pump.

b. Connect the P/S oil pressure switch connector.
62. INSTALL WATER INLET





63. INSTALL OIL LEVEL GAUGE GUIDE
a. Install a new O-ring to the oil level gauge guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push in the oil level gauge guide end into the guide hole of the oil pan.
d. Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Install the oil level gauge.
64. INSTALL AIR CLEANER ASSEMBLY
65. CONNECT VENTILATION HOSE NO.2
66. INSTALL FAN W/ FLUID COUPLING
67. INSTALL FAN AND GENERATOR V BELT
68. FULLY TIGHTEN FAN W/ FLUID COUPLING
69. INSTALL RADIATOR SUPPORT SEAL UPPER
70. INSTALL BATTERY
71. INSTALL DIFFERENTIAL CARRIER ASSEMBLY FRONT (4WD DRIVE TYPE)
72. INSTALL POWER STEERING LINK ASSEMBLY
73. ADD ENGINE OIL
74. ADD ENGINE COOLANT
75. CHECK FOR ENGINE OIL LEAKS
76. CHECK FOR ENGINE COOLANT LEAKS
77. INSTALL V-BANK COVER
a. Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
78. INSPECT IGNITION TIMING
SST 09843-18040