Removal And Installation
TIMING CHAIN
Removal and Installation
REMOVAL
1. Drain engine oil. Draining.
2. Drain engine coolant from inside engine. Engine Stand Setting.
3. Remove intake manifold collector. Exploded View.
4. Remove rocker covers (bank 1 and bank 2). Exploded View.
5. Remove oil pans (lower and upper) and oil strainer. Exploded View.
6. Remove drive belt, idler pulleys and bracket. Removal And Installation and Exploded View.
7. Remove power steering oil pump with piping connected, and temporarily secure it to aside. Exploded View.
8. Separate engine harness removing their brackets from front timing chain case.
9. Remove valve timing control covers.
- Loosen mounting bolts in the 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.
10. 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) (Arrow Indicates) 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.
Arrow Indicates : Engine front
- If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
11. Remove crankshaft pulley as follows:
a. Fix crankshaft with the pulley holder (commercial service tool)
(A).
1 : Crankshaft pulley
b. Loosen crankshaft pulley bolt and locate 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.
c. 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.
12. Remove front timing chain case as follows:
a. Loosen mounting bolts in the 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 in the figure.
c. Pry off case by moving the tool as shown.
- Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
CAUTION:
- Never use screwdrivers or something similar.
- After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
13. Remove water pump cover from front timing chain case.
- Use the seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
14. 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.
15. Remove O-ring (1) from rear timing chain case.
16. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (1).
b. Loosen upper mounting bolt (2) slowly, and then turn timing chain tensioner (primary) (3) on the mounting bolt so that plunger (4) 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).
17. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (primary).
18. Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves will strike the piston heads.
19. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2
(C) 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 tensioner (secondary), Exploded View. [Removing camshaft bracket (No. 1) is required.]
b. Remove camshaft sprockets (INT and EXH) mounting bolts.
- Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts.
CAUTION:
Never loosen 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.
- Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
- Insert 0.5 mm (0.020 in) thick metal or resin plate between timing chain and timing chain tensioner plunger (guide) (E).
Remove timing chain (secondary) (2) together with camshaft sprockets with timing chain loose from guide groove.
CAUTION:
Be careful of plunger coming-off when removing timing chain (secondary). This is because plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of fixed stopper pin.
NOTE:
- Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing chain (secondary).
- Figure is shown as an example of bank 1.
- When handling camshaft sprocket (INT), be careful of the following caution:
CAUTION:
- Handle carefully to avoid any shock to camshaft sprocket.
- Never disassemble. [Never loosen bolts (A) as shown in the figure].
20. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
- Remove timing chain tensioners (secondary) with a stopper pin attached.
21. Use a scraper to remove all traces of old liquid gasket from front timing chain case, and opposite mating surfaces.
- Remove old liquid gasket from bolt hole (B) and thread.
A : Remove sticking old liquid gasket
22. Use a scraper to remove all traces of old liquid gasket from water pump cover.
INSTALLATION
NOTE:
The below figure shows the relationship between the mating 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.
- Install timing chain tensioners (secondary) with a stopper pin attached and new O-ring.
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 nose, it is generally accepted camshaft is placed for the same direction of the figure.
CAUTION:
Hole on small dia side must be used for intake side dowel pin hole. Never misidentify (ignore big dia side).
3. Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin (A).
b. Install timing chain (secondary) (1) and camshaft sprockets (INT and EXH).
NOTE:
Figure shows bank 1 (rear view).
- Align the mating marks on timing chain (secondary) (orange link) with the ones on camshaft sprockets (INT and EXH)
(punched), and install them.
NOTE:
- Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary).
- There are two types of mating mark, circle and oval types.
They should be used for the bank 1 and bank 2, respectively.
- Align dowel pin on camshafts with the groove or hole on sprockets, and install them.
- On the intake side, align dowel pin on the camshaft front end with dowel pin hole on the back side of camshaft sprocket, and install them.
- On the exhaust side, align dowel pin on camshaft front end with dowel pin groove on camshaft sprocket, and install them.
- In case that positions of each mating mark and each dowel pin are not fit on mating 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.
- It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark (A) on the top of sprocket teeth and its extended line in advance with paint.
B : Mating mark (orange link)
c. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts.
- Secure camshaft using wrench at the hexagonal portion to tighten mounting bolts.
d. Pull stopper pins (B) out from timing chain tensioners (secondary) (1).
4. Install tension guide.
5. Install timing chain (primary) as follows:
a. Install crankshaft sprocket (1).
- Check the mating marks on crankshaft sprocket face the front of the engine.
b. Install timing chain (primary).
- Install timing chain (primary) so the mating mark (punched) (B) on camshaft sprocket (INT) (1) is aligned with the pink link (A) on timing chain, while the mating mark (notched) (C) on crankshaft sprocket (2) is aligned with the orange link (D) on timing chain, as shown in the figure.
3 : Water pump
- When it is difficult to align mating marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the mating marks.
- During alignment, be careful to prevent dislocation of mating mark alignments of timing chains (secondary).
6. Install internal chain guide (1) and slack guide (2).
3 : Tension guide
CAUTION:
Never over tighten slack guide mounting bolt (2). It is normal for a gap (A) to exist under the bolt seat when mounting bolt is tightened to specification.
7. 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 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.
8. Check again that the mating marks on each sprocket and each timing chain have not slipped out of alignment.
9. Install new O-rings (1) on rear timing chain case.
10. Install new front oil seal on front timing chain case.
- 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.
- Using a suitable drift [outer diameter: 60 mm (2.36 in)], 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.
11. Install water pump cover to front timing chain case.
- Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to water pump cover (1) as shown in the figure.
a : dia 2.3 - 3.3 mm (0.091 - 0.130 in)
Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.
12. Install front timing chain case as follows:
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. Fluid Type Specifications.
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
- There are two types of mounting bolt. Refer to the following for locating bolts.
d. After all bolts tightening, retighten them to the specified torque in numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
e. After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface.
- If not within the standard, repeat the installation procedure.
13. Install intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Being careful not to move seal rings from the installation grooves, align dowel pins on front timing chain case with the holes to install valve timing control covers.
c. Tighten mounting bolts in numerical order as shown in the figure.
14. Install crankshaft pulley as follows:
a. Install crankshaft pulley, taking care not to damage front oil seal.
- When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
b. Fix crankshaft with the pulley holder (commercial service tool).
c. Tighten crankshaft pulley bolt.
Troque: 44.1 N.m (4.5 kg-m, 33 ft-lb)
d. Place a paint mark (A) on crankshaft pulley (1) aligning with the angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90 degrees (angle tightening).
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.