Removal And Installation

TIMING CHAIN COVER

Removal and Installation


REMOVAL

1.Remove the upper oil pan. Removal And Installation.
2.Remove the intake valve timing control solenoid LH and RH. Intake Valve Timing Control Solenoid Valve (LH). (LH), and Intake Valve Timing Control Solenoid Valve (RH) (RH).
3.Remove the intake valve timing control position sensor LH and RH. Intake Valve Timing Control Position Sensor (LH) (LH), and Intake Valve Timing Control Position Sensor (RH) (RH).
4.Remove the camshaft position sensor (PHASE). Service and Repair.
5.Remove the crankshaft driven fan pulley and pulley bracket. Service and Repair
6.Remove the drive belt auto tensioner and idler pulley.





7.Remove the intake valve timing control solenoid valve cover (RH) (A) and intake valve timing control solenoid valve cover (LH) (B) as follows:
a.Loosen and remove the bolts in the reverse order as shown.
b.Cut the liquid gasket and remove the covers using Tool.
Tool number: KV-10111100 (J-37228)

CAUTION:
Do not damage mating surfaces.





8.Obtain compression TDC of No. 1 cylinder as follows:
a.Turn the crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with the timing indicator on the front cover.
9.Remove drive plate lower cover.





10.Loosen the crankshaft pulley bolts. Use Tool (A) to secure the crankshaft as shown.
Tool number- (J-47245)





a.Remove the crankshaft pulley from the crankshaft using suitable tool.
- Set the bolts in the two bolt holes [M6 x 1.0 mm (0.04 in)] on the front surface.
NOTE:
The dimension between the centers of the two bolt holes is 61
mm (2.40 in).





11.Remove the front cover.
a.Loosen and remove the bolts in the reverse order shown.
b.Cut the liquid gasket and remove the covers using Tool.
Tool number: KV-10111100 (J-37228)

CAUTION:
Do not damage mating surfaces.
12.Remove the front oil seal using suitable tool.

CAUTION:
Do not damage front cover.
13.Remove chain tensioner cover using Tool (if necessary).
Tool number: KV-10111100 (J-37228)

INSTALLATION






1.Install the front oil seal using suitable tool.

CAUTION:
Do not scratch or nick the oil seal.





2.Install the chain tensioner cover (if removed).
- Apply liquid gasket as shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products And Sealants.

CAUTION:
- The components must be installed within 5 minutes of the liquid gasket application.
- Then allow 30 minutes for the liquid gasket to set before operating the engine.





3.Install the front cover as follows:
a.Install a new O-ring on the cylinder block.

CAUTION:
Do not reuse O-ring.





b.Apply liquid gasket as shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products And Sealants.

CAUTION:
- The components must be installed within 5 minutes of the liquid gasket application.
- Then allow 30 minutes for the liquid gasket to set before operating the engine.
c.Check again that the timing alignment marks on the timing chain and on each sprocket are aligned. Then install the front cover.
d.Install the bolts in the numerical order as shown.





M6 x 50 mm (1.97 in): No. 1, 20, 25, 26, 27
M6 x 80 mm (3.15 in): No. 4, 5, 7
M6 x 20 mm (0.79 in): All except the above

e.After tightening, re-tighten to the specified torque.

CAUTION:
Be sure to wipe off any excessive liquid gasket oozing from the cover.





4.Install the intake valve timing control solenoid valve cover (RH)
(A) and intake valve timing control solenoid valve cover (LH) (B)
as follows:
- *: Cross mark (C) that cannot be seen after assembly a.Apply liquid gasket (D) as shown.

D: 2.6 - 3.6 mm (0.102 - 0.142 in) dia.

Use Genuine RTV Silicone Sealant or equivalent. Refer to
Recommended Chemical Products And Sealants.

CAUTION:
- The start and end of the liquid gasket application should be crossed at a position (C) that cannot be seen after attaching the cover.
- The components must be installed within 5 minutes of the liquid gasket application.
- Then allow 30 minutes for the liquid gasket to set before operating the engine.





b.Install the bolts in the numerical order as shown.
- (A): Intake valve timing control solenoid valve cover (RH)
- (B): Intake valve timing control solenoid valve cover (LH)
5.Install the crankshaft pulley.
- Install the key of the crankshaft.
- Insert the pulley by lightly tapping it.

CAUTION:
Do not tap pulley on the side surface where the belt is installed (outer circumference).
6.Tighten the crankshaft pulley bolt.





- Lock the crankshaft using tool (A), then tighten the bolt.
Tool number- (J-47245)
- Perform the following steps for angular tightening:
a.Apply engine oil onto the threaded parts of the bolt and seating area.





b.Select the one most visible notch of the four on the bolt flange.
Put an alignment mark (such as paint) on the crankshaft pulley to correspond to the selected notch.

Crankshaft pulley bolt torque
Step 1: 93.1 Nm (9.5 kg-m, 69 ft-lb)
Step 2: additional 90� (angle tightening)

7.Rotate the crankshaft pulley in normal direction (clockwise when viewed from engine front) to check for parts interference.
8.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: