Timing Cover: Service and Repair
FRONT TIMING CHAIN CASERemoval and Installation
NOTE:
^ This Information describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on the 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 install in reverse order of removal.
REMOVAL
1. Disconnect negative battery terminal.
2. Remove engine cover with power tool.
3. Remove air cleaner case assembly.
4. Remove front and rear engine undercover with power tool.
5. Release the fuel pressure.
6. Drain engine oil.
CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine oil on drive belts.
7. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when the engine is cold.
^ Do not spill engine coolant on drive belts.
8. Separate engine harnesses removing their brackets from front timing chain case.
9. Remove drive belts.
10. Remove intake manifold collectors (upper and lower).
11. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Refer to PS-27, "On-Vehicle Inspection and Service".
12. Remove power steering oil pump bracket.
13. Remove alternator.
14. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
15. Remove intake valve timing control covers.
^ Loosen mounting bolts in reverse order as shown in the figure.
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
16. Remove collared O-ring from front timing chain case (left and right side).
17. Remove rocker covers (right and left banks).
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
18. 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 (grooved line without color) with timing indicator.
b. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure.
^ If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
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.
19. Remove crankshaft pulley as follows:
a. Remove rear cover plate (2WD models) or starter motor (AWD models) and set ring gear stopper (SST).
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 as it will be used as a supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through.
CAUTION:
Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
20. Remove oil pan (lower).
21. Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order shown in figure.
22. Remove front timing chain case as follows:
a. Loosen mounting bolts with power tool in reverse order as shown in the figure.
b. Insert suitable tool into the notch at the top of front timing chain case as shown (1).
c. Pry off case by moving a tool as shown (2).
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
^ Do not use a screwdrivers or something similar.
^ After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
23. Remove O-rings from rear timing chain case.
24. Remove oil pan gasket (front).
25. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary.
^ Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
26. Remove front oil seal from front timing chain case using a suitable tool.
^ Use a screwdriver for removal.
CAUTION:
Exercise care not to damage front timing chain case.
27. Remove timing chain and related parts.
28. 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.
29. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
INSTALLATION
1. Install timing chain and related parts.
2. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
3. Install front oil seal on front timing chain case.
^ Apply new engine oil to the oil seal lip and dust seal lip.
^ Install it so that each seal lip is oriented as shown in the figure.
^ Using a suitable drift [outer diameter: 60 mm (2.36 in)], press fit oil seal until it becomes flush with front timing chain case end face.
^ Make sure the garter spring is in position and seal lip is not inverted.
4. Install water pump cover and chain tensioner cover to front timing chain case.
^ Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
5. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
b. Install new oil pan gasket (front).
^ Apply liquid gasket to oil pan gasket (front) as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
^ Align notch of front timing chain case with protrusion of oil pan gasket.
^ Apply liquid gasket with the tube presser (commercial service tool) to top surface of oil pan (upper) as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
c. Install new O-rings on rear timing chain case.
d. 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.
CAUTION:
Be careful that oil pan gasket is in place.
ii. Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily with holding front timing chain case from front and top as shown in the figure.
For bolt length and positions, refer to the step e.
iii. Same as the step ii, insert dowel pin with holding front timing chain case from front and top completely.
e. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
^ There are two types of mounting bolts. Refer to the following for locating bolts.
M8 bolts: 1, 2: 28.4 Nm (2.9 kg-m, 21 ft-lb)
M6 bolts: Except the above: 12.7 Nm (1.3 kg-m, 9 ft-lb)
f. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
6. Install two mounting bolts in front of oil pan (upper) in numerical order as shown in figure.
Torque: 17.2 Nm (1.8 kg-m, 13 ft-lb)
7. Install oil pan (lower).
8. Install intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to intake valve timing control covers as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
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 mounting bolts in numerical order as shown in the figure.
9. Install crankshaft pulley as follows:
a. Fix crankshaft using the ring gear stopper [SST: KV10117700 (J44716)].
b. 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).
c. Tighten crankshaft pulley bolt.
Torque: 44.1 Nm (4.5 kg-m, 33 ft-lb)
d. Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt.
e. Further tighten by 90 degrees. (Angle tightening)
^ Check the tightening angle by referencing to the notches. The angle between two notches is 90 degrees.
10. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
11. For the following operations, perform steps in the reverse order of removal.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/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.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less 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 fuel piping, check for fuel leakage at 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 chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
