Removal And Installation

FRONT TIMING CHAIN CASE


Removal and Installation


REMOVAL
1. Drain engine oil. Removal and Replacement.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine oil on drive belts.
2. Drain engine coolant from radiator. Service and Repair.

CAUTION:
- Perform this step when engine is cold.
- Do not spill engine coolant on drive belts.
3. Remove engine cooling fan (Motor driven type). Removal and Installation (Motor Driven Type).
4. Disconnect engine harnesses and remove harness brackets from front timing chain case.
5. Remove EVAP canister purge volume control solenoid valve, if necessary.
6. Remove drive belt. Removal And Installation.
7. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Power Steering Oil Pump.
8. Remove power steering oil pump bracket. Power Steering Oil Pump.
9. Remove generator. Removal and Installation.
10. Remove water bypass hoses and water hose clamp.
11. Remove engine cooling fan (Crankshaft driven type) and fan bracket. Removal and Installation (Crankshaft Driven Type).
12. Remove water hose at oil cooler.
13. Remove oil cooler water bypass pipe from front timing chain case. Exploded View.
14. Remove right and left intake valve timing control covers.





- Loosen bolts in reverse order as shown.
- Cut liquid gasket for removal using Tool.






CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.





15. Remove collared O-rings from front timing chain case (left and right side).
16. Remove A/C compressor bolts and temporarily secure A/C compressor aside. Service and Repair.
17. Remove crankshaft pulley as follows:
a. Remove rear cover and install Tool to hold ring gear in place.










b. Loosen crankshaft pulley bolt so that there is a 10 mm (0.39 in) gap between bolt and crankshaft pulley.

CAUTION:
Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect the crankshaft pulley from dropping.
c. Pull crankshaft pulley with both hands to remove it.





18. Loosen two bolts in front of oil pan (upper) in reverse order as shown.
19. Remove front timing chain case as follows:





a. Loosen bolts with power tool in reverse order as shown.





b. Insert suitable tool into the notch at the top of the front timing chain case as shown (1).
c. Pry off case by moving tool as shown (2).
- Cut liquid gasket for removal using Tool.






CAUTION:
- Do not use screwdriver or something similar.
- After removal, handle front timing chain case carefully so it does not twist, bend, or warp under a load.





20. Remove O-rings from rear timing chain case.
21. If necessary, remove water pump cover and chain tensioner cover from front timing chain case.
- Cut liquid gasket for removal using Tool.










22. Remove front oil seal from front timing chain case using suitable tool.

CAUTION:
Be careful not to damage front timing chain case.
23. Remove idler pulley, if necessary. Service and Repair.





24. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, oil pan (upper), and liquid gasket mating surfaces.

CAUTION:
Be careful not to allow gasket fragments to enter oil pan.





- Remove old liquid gasket from bolt hole and thread.





25. Use a scraper to remove all traces of old liquid gasket from water pump cover, chain tensioner cover (if necessary) and intake valve timing control covers.

INSTALLATION





1. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.

NOTE:
Be sure to place dowel pins in the original holes in front timing chain case.
2. Install new front oil seal on the 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.





- Press-fit oil seal until it becomes flush with front timing chain case end face using suitable drift [outer diameter: 60 mm (2.36 in)].
- Make sure the garter spring is in position and seal lip is not inverted.

CAUTION:
- Be careful not to damage front timing chain case and crankshaft.
- Press-fit straight and avoid causing burrs or tilting oil seal.
3. Install water pump cover and chain tensioner cover to front timing chain case, if removed.





- Apply a continuous bead of liquid gasket using Tool to front timing chain case as shown.
Use Genuine RTV Silicone Sealant or equivalent. Recommended Chemical Products And Sealants.






4. Install idler pulley, if removed.
5. Install front timing chain case as follows:





a. Apply a continuous bead of liquid gasket using Tool to front timing chain case back side as shown.
Use Genuine RTV Silicone Sealant or equivalent. Recommended Chemical Products And Sealants.










b. Install new O-rings on rear timing chain case.
c. Assemble front timing chain case as follows:





i. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely.





ii. Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily while holding front timing chain case from front and top as shown.
iii. Same as the previous step, insert dowel pin while holding front timing chain case from front and top completely.





d. Tighten bolts to the specified torque in numerical order as shown.
e. After all bolts are tightened, retighten them to the specified torque in numerical order as shown.
- There are two type of bolts.










6. Install two bolts in front of oil pan (upper) in numerical order as shown.






7. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.





b. Apply a continuous bead of liquid gasket using Tool to intake valve timing control covers as shown.
Use Genuine RTV Silicone Sealant or equivalent. Recommended Chemical Products And Sealants.










c. Install new collared O-rings in front timing chain case oil hole
(left and right sides).
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers.





e. Tighten bolts in numerical order as shown.
8. Install crankshaft pulley as follows:
a. 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).
b. Tighten crankshaft pulley bolt in two steps.






c. Remove Tool to release the ring gear and install the rear cover plate. Exploded View.






9. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
10. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: