Timing Chain: Service and Repair
Removal and InstallationEM-199 Component (Part 1):
EM-199 Component (Part 2):
REMOVAL
1. Remove engine assembly from vehicle.
2. Remove the following components and related parts:
^ Drive belt auto tensioner and idler pulley
^ Thermostat housing and hoses
^ Ignition coil
^ Rocker cover
3. If necessary, remove intake valve timing control position sensor (right and left bank) and camshaft position sensor (PHASE) from intake valve timing control cover and front cover.
CAUTION:
^ Handle carefully to avoid dropping and shocks.
^ Do not disassemble.
4. If necessary, remove intake valve timing control solenoid valve from intake valve timing control cover.
CAUTION:
^ Handle components and parts carefully to avoid dropping and shocks.
^ Do not disassemble.
^ Do not allow metal powder to adhere to magnetic part at sensor tip.
^ Do not place sensors in a location where they are exposed to magnetism.
5. Remove intake valve timing control cover as follows:
a. Loosen and remove mounting bolts in the reverse order as shown in the figure.
b. Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
^ Exercise care not to damage mating surfaces.
^ Pull out cover keeping levelness without an angle, as inner part of cover is engaged with the center of camshaft sprocket (INT).
6. Remove O-rings from front cover.
7. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with timing indicator on front cover.
b. Make sure that both intake and exhaust cam noses of No. 1 cylinder (engine front side of left bank) are located as shown in the figure.
^ If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
8. Remove crankshaft pulley as follows:
a. Remove rear plate cover, and set ring gear stopper (SST).
b. Loosen crankshaft pulley bolt, and then pull crankshaft pulley with both hands to remove it.
CAUTION:
^ Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect removed crankshaft pulley from dropping.
^ Do not remove balance weight (inner hexagon bolt) at the front of crankshaft pulley.
9. Remove oil pan and oil strainer.
10. Remove front cover as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
^ Exercise care not to damage mating surfaces.
^ After removal, handle front cover carefully so it does not tilt, cant, or warp under a load.
11. Remove front oil seal from front cover using suitable tool.
^ Use screwdriver for removal.
CAUTION:
Be careful not to damage front cover.
12. Remove O-rings from cylinder heads (right and left bank) and cylinder block.
13. Remove chain tensioner cover from front cover.
^ Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for remove.
14. Remove oil pump drive spacer.
^ Set bolts in the two bolt holes [M6 x pitch 1.0 mm (0.04 in)] on front surface. Using suitable puller, pull oil pump drive spacer off from crankshaft.
NOTE:
The dimension between the centers of the two bolt holes is 33 mm (1.30 in).
In the figure, a commercial steering puller is used.
15. Remove oil pump.
16. Remove chain tensioner (left bank) as follows:
NOTE:
To remove timing chain and related parts, start with those on left bank. The procedure for removing parts on right bank is omitted because it is the same as that for left bank.
a. Press tab in the direction of arrow (or turn lever in the direction of arrow) to unlock the locking with the groove that stops tensioner plunger from returning.
^ Lightly press tensioner plunger to release the tension of spring for this operation.
b. Push in tensioner plunger to align the hole on lever and that on pump main body.
^ Pushing in tensioner too far does not allow the holes to align. Therefore, push in plunger to the degree at which the start of stopper groove and tab engages.
c. Insert stopper pin [hard wire with approx. 0.5 mm (0.020 in) diameter or similar tool] to fix plunger. With plunger fixed, remove chain tensioner.
17. Remove chain tension guide and timing chain slack guide.
18. Remove timing chain and crankshaft sprocket.
CAUTION:
After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike the piston head.
19. With hexagonal part of camshaft locked with wrench, loosen mounting bolts securing camshaft sprocket to remove camshaft sprocket.
CAUTION:
Do not loosen mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
20. Perform same procedure as for left bank, remove timing chain and related parts on right side.
21. Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces.
^ Remove oil liquid gasket from bolt hole and thread.
22. Use scraper to remove all trace of liquid gasket from chain tensioner cover and intake valve timing control covers.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and any excessive wear at link plates and roller links of timing chain. Replace timing chain as necessary.
INSTALLATION
NOTE:
^ The above figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.
^ Parts with an identification mark (R or L) should be installed on the corresponding bank according to the mark.
Parts with an identification mark:
^ Camshaft sprocket (INT)
^ Dowel pin groove of camshaft sprocket (EXH) (camshaft sprocket is same part both banks)
^ Chain tension guide
^ Chain slack guide
^ To install timing chain and related parts, start with those on right bank. The procedure for installing parts on left bank is omitted because it is the same as that for installation on right bank.
1. Make sure that crankshaft key and dowel pin of each camshaft are located as shown in the figure. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
Camshaft dowel pin: At cylinder head upper face side in each bank
Crankshaft key: At cylinder head side of left bank
2. Install camshaft sprockets.
^ Install onto correct side by checking with identification mark on surface.
^ Install camshaft sprocket (EXH) by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.)
^ Lock the hexagonal part of camshaft in the same procedure as for removal, and tighten mounting bolts.
3. Install crankshaft sprockets for both banks.
^ Install each crankshaft sprocket so that its flange side (the larger diameter side without teeth) faces in the direction shown in the figure.
NOTE:
The same parts are used but facing directions are different.
4. Install timing chains and related parts.
^ Align the mating mark on each sprocket and timing chain for installation.
NOTE:
Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.
CAUTION:
For the above reason, after the mating marks are aligned, keep them aligned by holding them with a hand.
^ Install slack guides and tension guides onto correct side by checking with identification mark on surface.
^ Install chain tensioner with plunger fixed as described in its removal.
CAUTION:
^ Before and after the installation of chain tensioner, make sure that the mating mark on timing chain is not out of alignment.
^ After installing chain tensioner, remove stopper pin to release tensioner. Make sure tensioner is released.
^ To avoid chain-link skipping of timing chain, do not move crankshaft or camshafts until front cover is installed.
5. Perform the same procedure as for right bank, install timing chain and related parts on left side.
6. Install oil pump.
7. Install oil pump drive spacer as follows:
a. Insert oil pump drive spacer according to the directions of crankshaft key and the two flat surfaces of oil pump inner rotor.
^ If the positional relationship does not allow the insertion, rotate oil pump inner rotor with a finger to allow spacer.
b. After confirming that the position of each part is in correct condition to allow for spacer, force fit spacer by lightly tapping with plastic hammer until it contacts and does not go further.
8. Install front oil seal on front cover.
^ Apply new engine oil to both oil seal lip and dust seal lip.
^ Install it so that each seal lip is oriented as shown in the figure.
CAUTION:
Be careful not to scratch or make burrs on circumference of oil seal.
^ Using front oil seal drift (commercial service tool), press fit until the height of front oil seal is level with the mounting surface.
Front oil seal drift
Outer diameter: 56 mm (2.20 in)
Inner diameter: 49 mm (1.93 in)
^ Make sure the garter spring is in position and seal lips not inverted.
9. Install chain tensioner cover to front cover.
^ Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to front cover as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
10. Install front cover as follows:
a. Install new O-rings onto cylinder heads (right and left bank) and cylinder block.
b. Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to front cover as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
c. make sure again that the mating marks on timing chain and that on each sprocket are aligned. Then, install front cover.
CAUTION:
Be careful to avoid interference with the front end of oil pump drive spacer. Such interference may damage front oil seal.
d. Tighten mounting bolts in numerical order as shown in the figure.
^ There are four type mounting bolts.
e. After all mounting bolts are tightened, retighten them in numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan.
11. Install intake valve timing control cover as follows:
a. At the back of intake valve timing control cover, install new seal rings (three for each bank) to the area to be inserted into camshaft sprocket (INT).
CAUTION:
Do not spread seal ring excessively to avoid breaks and deformation.
b. Install new O-rings on front cover.
c. Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to intake valve timing control covers as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
d. Tighten mounting bolts in numerical order as shown in the figure.
12. Install intake valve timing control position sensor, intake valve timing control solenoid valve and camshaft position sensor (PHASE) to intake valve timing control cover and front cover if removed.
^ Be sure to tighten mounting bolts with flanges completely seated.
13. Install oil pan and oil strainer.
14. Install crankshaft pulley as follows:
a. Fix crankshaft with ring gear stopper [SST: J-45476].
b. Install crankshaft pulley, taking care not to damage front oil seal.
^ Install according to dowel pin of oil pump drive spacer.
^ Lightly tapping its center with plastic hammer, insert pulley.
CAUTION:
Do not tap pulley on the side surface where belt is installed (outer circumference).
c. Apply engine oil onto threaded parts of crankshaft pulley bolt and seating area.
d. Tighten crankshaft pulley bolt.
Torque: 93.1 Nm (9.5 kg-m, 69 ft-lb)
e. Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt.
f. Further tighten by 90 degrees. (Angle tightening)
^ Check the tightening angle by referencing to the notches. The angle between two notches is 90 degrees.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
16. Install in the reverse order of removal after this step.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak and exhaust gases 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.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, 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.
