Removal

TIMING CHAIN

REMOVAL

1.Release the fuel pressure. Testing and Inspection.
2.Disconnect the battery cable from the negative terminal.
3.Remove engine cover, using a power tool. Exploded View.
4.Remove radiator reservoir tank. Exploded View.
5.Remove air duct and air cleaner case assembly (RH and LH). Exploded View.
6.Remove engine undercover, using a power tool.
7.Drain engine coolant from radiator. Draining Engine Coolant.

CAUTION:
- Perform this step when the engine is cold.
- Never spill engine coolant on drive belt.
8.Remove radiator hose (upper and lower). Exploded View.
9.Drain engine oil. Draining.

CAUTION:
- Perform this step when the engine is cold.
- Never spill engine oil on drive belt.
10.Remove drive belt. Exploded View.
11.Remove radiator cooling fan assembly. Exploded View.
12.Separate engine harnesses removing their brackets from front timing chain case.
13.Remove intake manifold collector. Exploded View.
14.Remove intake manifold. Exploded View.
15.Remove fuel sub tube mounting bolt. 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.
Exploded View.
19.Remove power steering oil pump bracket. Exploded View.
20.Remove idler pulley, auto tensioner and bracket. Exploded View.
21.Remove alternator and alternator bracket. Exploded View (2WD models) or
Exploded View (AWD models).
22.Remove water outlet (front) and water piping. Exploded View.
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:
- Never 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). 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. Exploded View. (AWD models)
b.Remove power steering pipe mounting bolt. Service and Repair.





c.Remove rear cover plate and set the ring gear stopper [SST:
KV-10118600 (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). Exploded View (2WD models) or {LINK_TO_MANY:0000000007457992}{LINK_TO_MANY:0000000007457993}, "Exploded
View (AWD)" (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: KV-10111100 (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:
Never 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
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). 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.