Installation

TIMING CHAIN

Removal and Installation


INSTALLATION


CAUTION:
Do not reuse O-rings.
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. 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 per the following:

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 an 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 per the following:





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.

CAUTION:





Do not reuse O-rings.





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 per the following:
- 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 an equivalent. 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 an equivalent. 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 must 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.





f.After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.

CAUTION:
Be sure to wipe out 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: Exploded View.

11.Install valve timing control covers (bank 1 and bank 2) as per the following:





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: Exploded View.

- After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
12.Install oil pan (lower). Exploded View.
13.Install rocker covers (bank 1 and bank 2). Exploded View.
14.Install crankshaft pulley as per the following:
a.Fix crankshaft using the ring gear stopper [SST: KV-10118600 (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.









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 drive belt auto-tensioner bracket (1) and power steering oil pump bracket (2) as per the following:





a.Install drive belt auto-tensioner bracket, and tighten mounting bolts No. 2, 3. (temporarily)
b.Tighten mounting bolts No. 2, 3. (specified torque)
c.Install power steering oil pump bracket, and tighten mounting bolts No. 1, 4, 5. (temporarily)
d.Tighten mounting bolts No. 1. (specified torque)
e.Tighten mounting bolts No. 4, 5. (specified torque)
16.For the following operations, perform steps in the reverse order of removal.