Removal And Installation
TIMING CHAIN
Removal and Installation
REMOVAL
1. Release fuel pressure. Testing and Inspection.
2. Drain engine coolant from radiator. Draining Engine Coolant.
3. Remove fan shroud (lower). Exploded View.
4. Remove fan bracket. Exploded View.
5. Remove drive belt auto-tensioner. Exploded View.
6. Remove oil level gauge and oil level gauge guide. Exploded View.
7. Move power steering oil pump to the position without the hindrance for work. Exploded View.
8. Remove alternator, alternator bracket and alternator stay. Exploded View.
9. Move power steering reservoir tank to the position without the hindrance for work, and then remove Reservoir tank bracket. Service and Repair.
10. Remove camshaft position sensors.
A : Keep free from magnetic materials
CAUTION:
- Handle carefully to avoid dropping and shocks.
- Never disassemble.
- Never allow metal powder to adhere to magnetic part at sensor tip.
- Never place sensors in a location where they are exposed to magnetism.
11. Remove high pressure fuel pump and lifter. Exploded View.
CAUTION:
After removing lifter, replace lifter with a new one.
12. Remove radiator hose (upper) and radiator hose (lower). Exploded View.
13. Remove water suction pipe. Exploded View.
14. Remove valve timing control cover as per the following:
a. Disconnect valve timing control solenoid valve harness connector.
b. Loosen mounting bolts in the reverse order as shown in the figure.
A : Bank 2
B : Bank 1
C : Dowel pin hole
CAUTION:
- Exercise care not to damage mating surfaces.
- Shaft is internally jointed with camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected.
15. Remove intake valve timing control solenoid valve (bank 1 and bank 2), if necessary.
CAUTION:
Valve timing control solenoid valve is not reusable. Never remove it unless required.
16. Remove O-rings (1) from front cover.
17. Remove rocker cover. Exploded View.
18. Obtain No. 1 cylinder at TDC of its compression stroke. Service and Repair.
19. Remove crankshaft pulley. Service and Repair.
20. Remove water pump pulley. Exploded View.
21. Remove oil pan (lower) and oil strainer. Exploded View.
22. Remove oil pan (upper). Exploded View.
23. Remove front cover as per the following:
a. Loosen mounting bolts (A), and then remove camshaft bracket
(1).
b. Loosen mounting bolts in reverse order as shown in the figure.
c. Insert a suitable tool into the notch at front cover.
- Pry off case by moving a suitable tool.
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.
24. Remove oil pump and oil pump drive spacer.
25. Remove front oil seal from front cover using suitable tool.
- Use screwdriver for removal.
CAUTION:
Be careful not to damage front cover.
26. Remove O-rings (1), (2), (3) from cylinder heads and cylinder block.
27. Remove oil filter (for valve timing control solenoid valve), if necessary.
28. Remove timing chain tensioner cover from front cover, if necessary.
- Use seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
29. Remove timing chain tensioner (bank 1) as per the following:
NOTE:
To remove timing chain and related parts, start with those on bank 1. The procedure for removing parts on bank 2 is omitted because it is the same as that for bank 1.
a. Push both sides of spring (A) against spring tension, and then press in plunger with a slack guide (2).
1 : Timing chain tensioner (bank 1)
b. Insert a stopper pin (A) into the body hole, and then fix it with the plunger pushed in.
30. Remove high pressure fuel pump camshaft.
31. Remove tension guide and slack guide.
32. Remove exhaust camshaft sprocket as per the following:
- Secure the hexagonal portion of exhaust camshaft using a wrench to loosen mounting bolt.
33. Remove timing chain and crankshaft sprocket.
CAUTION:
After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike the piston head.
34. Remove intake camshaft sprocket as per the following:
- Secure the hexagonal portion (located in between journal No.1 and journal No. 2) of drive shaft (A) using a wrench (B) to loosen mounting bolt.
Arrow : Engine front
NOTE:
The figure shows an example of bank 2.
CAUTION:
- Never loosen the mounting bolt by securing anything other than the camshaft (drive shaft) hexagonal portion or with tensioning the timing chain.
- When holding the hexagonal part of camshaft (drive shaft) with a wrench, be careful not to allow the wrench to cause interference with other parts.
- Never disassemble camshaft sprocket. [Never loosen bolts
(B) as shown in the figure.]
A : Intake
35. Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces.
- Remove old liquid gasket from bolt hole and thread.
A : Remove old liquid gasket that is stuck
B : Bolt hole
INSTALLATION
NOTE:
- The above figure shows the relationship between the matching 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.
- Intake camshaft sprocket, exhaust camshaft sprocket
- Tension guide
- Slack guide
- To install timing chain and related parts, start with those on bank 2. The procedure for installing parts on bank 1 is omitted because it is the same as that for installation on bank 2.
1. Check that crankshaft key (1) and dowel pin (A) of each camshaft are located as shown in the figure.
Camshaft dowel pin : At cylinder head upper face side in each bank
Crankshaft key : Straight up
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.
2. Install camshaft sprockets (INT and EXH).
- Install onto correct side by checking with identification mark
(A) on surface.
Exhaust side:
- Secure the hexagonal portion of exhaust camshaft using a wrench to tighten mounting bolt. Exploded View.
Intake side:
- Secure the hexagonal portion (located in between journal No.1 and journal No. 2) of drive shaft (A) using a wrench (B) to tighten mounting bolt. Exploded View.
Arrow : Engine front
NOTE:
The figure shows an example of bank 2.
3. Install high pressure fuel pump camshaft.
4. Install timing chains as per the following:
a. Install crankshaft sprockets for both banks.
- Install each crankshaft sprocket so that its flange side (the larger diameter side without teeth) (A) faces in the direction shown in the figure.
1 : Crankshaft sprocket (bank 1 side)
2 : Crankshaft sprocket (bank 2 side)
NOTE:
The same parts are used but facing directions are different.
b. Install timing chains.
Bank 2 (F):
- Install timing chain so that the matching mark (punched) (B) and the matching mark (outer groove) (C) on camshaft sprocket is aligned with the copper link (A) on timing chain, while the matching mark (punched) (B) on crankshaft sprocket is aligned with the yellow link (D) one on timing chain, as shown in the figure.
Bank 1 (G):
- Install timing chain so that the matching mark (punched) (B) and the matching mark (outer groove) (C) on camshaft sprocket is aligned with the copper link (A) on timing chain, while the matching mark (notched) (E) on crankshaft sprocket is aligned with the yellow link (D) one on timing chain, as shown in the figure.
5. Install slack guides and tension guides onto correct side by checking with identification mark (A) on surface.
1 : Slack guide (bank 2)
2 : Tension guide (bank 2)
3 : Slack guide (bank 1)
4 : Tension guide (bank 1)
CAUTION:
Never overtighten slack guide mounting bolt (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolt are tightened to the specification.
1 : Slack guide
3 : Cylinder block
6. Install timing chain tensioner as per the following:
a. Fix the plunger at the most compressed position using a stopper pin (A).
- Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner.
b. Pull out stopper pin 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 oil pump and oil pump drive spacer. Exploded View.
9. Install front oil seal on front cover. Service and Repair.
10. Install timing chain tensioner cover (2) to front cover (1).
a : f3.4 - 4.4 mm (0.134 - 0.173 in)
- 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. Recommended Chemical Products And Sealants.
11. Install oil filter (for valve timing control solenoid valve) (1) in the direction shown in the figure, if removed.
- Check that the oil filter does not protrude from the upper surface of front cover (2) after installation.
12. Install front cover as per the following:
a. Install new O-ring (1), (2), (3) onto cylinder heads 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. Recommended Chemical Products And Sealants.
A : Junction between cylinder block and cylinder head
B : Protrusion
c : 4.3 - 5.3 mm (0.169 - 0.209 in)
d : f3.4 - 4.4 mm (0.134 - 0.173 in)
e : f4.0 - 5.6 mm (0.157 - 0.220 in)
f : f4.8 - 5.8 mm (0.189 - 0.228 in)
c. Check again that the matching marks on timing chain and that on each sprocket are aligned. Then, install front cover.
CAUTION:
Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Tighten mounting bolts in numerical order as shown in the figure.
- There are three types of mounting bolts.
A : 0.79 in (0.79 in)
B : 1.77 in (1.77 in)
C : 3.15 in (3.15 in)
e. After all mounting bolts are tightened, retighten them in numerical order as shown in the figure.
CAUTION:
Be sure to wipe out any excessive liquid gasket leaking onto surface mating with oil pan.
13. Install valve timing control cover as per the following:
- Bolt (A) of fuel pump connector protector (1) cannot be installed after installing valve timing control cover. Therefore, install fuel pump connector protector in advance, if it is being removed.
a. Install new O-rings (1) on front cover.
b. Install new seal rings (1) in shaft grooves.
CAUTION:
When replacing seal ring, replace all rings with new ones.
c. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to valve timing control covers as shown in the figure.
A : Bank 1
B : Bank 2
c : f3.4 - 4.4 mm (0.134 - 0.173 in)
Use Genuine RTV silicone sealant or equivalent. Recommended Chemical Products And Sealants.
d. Being careful not to move seal ring from the installation groove, align dowel pins on front cover with dowel pin holes (C) to install valve timing control covers.
A : Bank 2
B : Bank 1
e. Tighten mounting bolts in numerical order as shown in the figure.
14. Install camshaft position sensor and valve timing control solenoid valve (RH and LH) to valve timing control cover, if removed.
- Be sure to tighten mounting bolts with flanges completely seated.
15. Install oil pan (upper). Exploded View.
16. Install oil pan (lower) and oil strainer. Exploded View.
17. Install water pump pulley. Exploded View.
18. Install crankshaft pulley.
- Fix the crankshaft as instructed in the removal procedure. Service and Repair.
a. Install crankshaft pulley, taking care not to damage front oil seal.
b. Apply engine oil onto threaded parts of crankshaft pulley bolt and seating area.
- Lightly tapping its center with plastic hammer, insert crankshaft pulley.
CAUTION:
Never tap crankshaft pulley on the side surface where belt is installed (outer circumference).
c. Tighten crankshaft pulley bolt.
Tightening torque: 205 N-m (21 kg-m, 151 ft-lb)
d. Put a paint mark (A) on crankshaft pulley (1) aligning with angle mark (B) on crankshaft pulley bolt.
e. Tighten crankshaft pulley bolt (clockwise).
Angle tightening: 90 degrees (c)
- Check the tightening angle by referencing to the notches. The angle between two notches is 90 degrees.
19. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
20. Install in the reverse order of removal.