Removal and Installation
TIMING CHAIN
Removal and Installation
REMOVAL
1. Release the fuel pressure. Refer to Testing and Inspection.
2. Disconnect the battery cable from the negative terminal.
3. Remove engine cover with power tool. Refer to Exploded View.
4. Remove radiator reservoir tank. Refer to Exploded View.
5. Remove air duct and air cleaner case assembly (RH and LH). Refer to Exploded View.
6. Remove engine undercover with power tool.
7. Drain engine coolant from radiator. Refer to Draining.
CAUTION:
- Perform this step when the engine is cold.
- Never spill engine coolant on drive belt.
8. Remove radiator hose (upper and lower). Refer to Exploded View.
9. Drain engine oil. Refer to Draining.
CAUTION:
- Perform this step when the engine is cold.
- Never spill engine oil on drive belt.
10. Remove drive belt. Refer to Exploded View.
11. Remove radiator cooling fan assembly. Refer to Exploded View.
12. Separate engine harnesses removing their brackets from front timing chain case.
13. Remove intake manifold collector. Refer to Exploded View.
14. Remove intake manifold. Refer to Exploded View.
15. Remove fuel sub tube mounting bolt. Refer to Exploded View.
16. Remove oil level gauge and oil level gauge guide.
17. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to Exploded View.
18. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Refer to Exploded View.
19. Remove power steering oil pump bracket. Refer to Exploded View.
20. Remove idler pulley, auto tensioner and bracket. Refer to Exploded View.
21. Remove alternator and alternator bracket. Refer to 2WD models) or Exploded View (AWD models).
22. Remove water outlet (front) and water piping. Refer to Service and Repair.
23. Remove valve timing control covers (bank 1 and bank 2) and gasket as follows:
a. Disconnect valve timing control harness connector.
b. Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
c. Shaft is engaged with intake side camshaft sprocket center hole on inside. pull straight out so as not to tilt until the joint is disengaged.
- The mating surface of magnet retarder (2) may be fitted with the exhaust side camshaft sprocket via the engine oil. Open valve timing control cover (1) carefully
- If the mating surface of magnet retarder is fitted with the camshaft sprocket, open the cover within the range that the load is not applied to the harness. And then, remove it so as to prevent magnet retarder from dropping.
CAUTION:
- Be careful not to damage magnet retarder.
- When carrying valve timing control cover, face the magnet retarder side up to prevent the cover from falling from magnet retarder.
- Never remove magnet retarder from valve timing control cover. (Disassembly prohibited parts)
24. Remove rocker covers (bank 1 and bank 2). Refer to Exploded View.
25. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of bank 1) are located as shown in the figure.
- If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
26. Remove crankshaft pulley as follows:
a. Remove front cross bar. Refer to Exploded View. (AWD models)
b. Remove power steering pipe mounting bolt.
c. Remove rear cover plate and set the ring gear stopper [SST:
KV10118600 (J-48641)] (A) as shown in the figure.
d. Loosen crankshaft pulley bolt and rotate bolt seating surface at
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.
e. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
27. Remove oil pan (lower). Refer to Exploded View (2WD models) or Exploded View (AWD models).
28. Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order as shown in the figure.
29. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Insert a suitable tool (A) into the notch at the top of front timing chain case as shown.
c. Pry off case by moving the suitable tool as shown.
- Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
CAUTION:
- Never use a screwdriver or something similar.
- After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
30. Remove front oil seal from front timing chain case using a suitable tool.
- Use a screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
31. Remove O-rings (1) from rear timing chain case.
32. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (A).
b. Loosen upper mounting bolt (B) slowly, and then turn timing chain tensioner (primary) (1) on the upper mounting bolt so that plunger (C) is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain tensioner (primary).
33. Remove internal chain guide (1), and slack guide (2).
34. Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain tensioner (primary), never turn crankshaft and camshaft separately, or valves will strike the piston heads.
35. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin (2) to the timing chain tensioners
(secondary) (1).
NOTE:
- Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.
- For removal of timing chain tensioners (secondary), refer to EM-67, "Exploded View". [Removing camshaft bracket (No. 1) is required.]
b. Remove camshaft sprocket mounting bolts (INT and EXH).
- Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts.
CAUTION:
Never loosen the mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
c. Remove timing chain (secondary) together with camshaft sprockets.
CAUTION:
Never disassemble. [Never loosen bolts (A) and (B) as shown in the figure.]
36. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to Exploded View.
b. Remove timing chain tensioners (secondary) with a stopper pin attached.
37. 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.
38. Remove old liquid gasket from bolt hole and thread.
INSTALLATION
NOTE:
The below figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to Exploded View.
2. Check that dowel pin (A) and crankshaft key (1) 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 noses, 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 bank 1.
3. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it pressed in with a stopper pin (A).
b. Install timing chains (secondary) and camshaft sprockets.
- Align the matching marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets
(punched), and install them.
NOTE:
- Figure shows bank 1 (rear view).
- Matching marks for camshaft sprockets are on the back side of camshaft sprockets (secondary).
- There are two types of matching marks, circle and oval types. They should be used for the bank 1 and bank 2, respectively.
Bank 1 : Use circle type.
Bank 2 : Use oval type.
- Align dowel pin camshafts with the groove or dowel hole on sprockets, and install them.
- On the intake side, align dowel pin on camshaft front end with pin groove on the back side of camshaft sprocket, and install them.
- On the exhaust side, align dowel pin on camshaft front end with pin hole on camshaft sprocket, and install them.
- In case that positions of each matching mark and each dowel pin are not fit on matching parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
- Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.
- Check the matching marks (punched) (D) on each camshaft sprocket are positioned on the matching marks (orange link)
(C) on timing chain (secondary).
NOTE:
Matching mark (punched) in the figure is for checking loose at this step.
c. After confirming the matching marks are aligned, tighten camshaft sprocket mounting bolts.
- Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts.
d. Pull stopper pins (2) out from timing chain tensioners (secondary) (1).
4. Install timing chain (primary) as follows:
a. Install crankshaft sprocket (1).
- Check the matching marks on crankshaft sprocket face the front of the engine.
b. Install timing chain (primary).
- Install timing chain (primary) so the matching mark (punched)
(B) on camshaft sprocket (INT) (1) is aligned with the yellow link (A) on timing chain, while the matching mark (notched) (C) on crankshaft sprocket (2) is aligned with the orange link (D) one on timing chain, as shown in the figure.
- When it is difficult to align matching marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the matching marks.
- During alignment, be careful to prevent dislocation of matching mark alignments of timing chains (secondary).
5. Install internal chain guide (1), slack guide (2).
CAUTION:
Never overtighten slack guide mounting bolts (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolts are tightened to the specification.
6. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B).
- The lever parts and the plunger stopper tab are synchronized.
Therefore, the plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
e. Install timing chain tensioner (primary) (1).
- Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary).
f. Pull out stopper pin (A) after installing, and then release plunger.
7. Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.
8. Install new O-rings (1) on rear timing chain case.
9. Install new front oil seal on front timing chain case.
- Apply new engine oil to both oil seal lip (A) and dust seal lip
(B).
- 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)] (A), press-fit oil seal until it becomes flush with front timing chain case end face.
- Check the garter spring is in position and seal lip is not inverted.
10. Install front timing chain case as follows:
- Check O-rings stay in place during installation to rear timing chain case.
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. Refer to Recommended Chemical Products and Sealants.
b. Apply liquid gasket to top surface of oil pan (upper) as shown in the figure.
Use Genuine RTV silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.
c. Assemble front timing chain case.
CAUTION:
- Be careful not to damage front oil seal by interference with front end of crankshaft.
- Attaching should be done within 5 minutes after liquid gasket application.
d. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
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.
M10 bolts : 1, 2, 3, 4, 5, 6, 7
Torque: 55.0 Nm (5.6 kg-m, 41 ft-lb)
M6 bolts : Except the above
Torque: 12.7 Nm (1.3 kg-m, 9 ft-lb)
f. After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
g. Install two mounting bolts in front of oil pan (upper) in numerical order shown in the figure.
Tightening torque : Refer to EM-97, "2WD : Exploded View". Exploded View
11. Install valve timing control covers (bank 1 and bank 2) as follows:
a. Install new seal rings (1) in shaft grooves.
CAUTION:
When replacing seal ring, replace all rings with new one.
b. To check the joint between dowel pins and dowel pin holes, check the looseness in the axle direction by pushing the circumferential looseness (between dowel pins and dowel pin holes) by twisting in the circumferential direction.
CAUTION:
Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose.
c. Install valve timing control cover with new gasket to front timing chain case.
CAUTION:
- Never face the magnet retarder side down to prevent magnet retarder from dropping.
- Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign materials.
- Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then insert them.
- Be careful not to drop the seal ring from the shaft groove.
- When setting the valve timing control cover in position by hand, if valve timing control cover is not contacting with the front timing chain case, the dowel pin of magnet retarder may not be aligned with the dowel pin holes of cover. In this case, return to step "b".
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with holes to install valve timing control covers.
e. Tighten mounting bolts in numerical order as shown in the figure.
Tightening torque : Refer to EM-50, "Exploded View". Exploded View
- After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
12. Install oil pan (lower). Refer to Exploded View (2WD models) or Exploded View (AWD models).
13. Install rocker covers (bank 1 and bank 2). Refer to Exploded View.
14. Install crankshaft pulley as follows:
a. Fix crankshaft using the ring gear stopper [SST: KV10118600 (J-48641)].
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. Place a matching mark (A) on crankshaft pulley (2) aligning with the matching mark (C) of crankshaft pulley bolt (1). Tighten the bolt 90 degrees (one marks) (b).
e. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
15. Install power steering oil pump bracket and idler pulley bracket as follows:
a. Tighten mounting bolts in numerical order as shown in the figure. (temporarily)
b. Tighten mounting bolts to specified torque in numerical order as shown in the figure.
16. For the following operations, perform steps in the reverse order of removal.