Timing Chain: Service and Repair

TIMING CHAIN






Removal and Installation

CAUTION: Apply new engine oil to parts marked in illustration before installation.

REMOVAL
1. Release the fuel pressure. Refer to FUEL PRESSURE RELEASE.
2. Remove the air cleaner and air duct assembly.
3. Remove the spark plugs.
4. Remove the rocker cover.
5. Remove the coolant overflow reservoir tank.
6. Remove the auxiliary drive belt auto-tensioner. Refer to Removal and Installation of Drive Belt Auto-tensioner.
7. Remove the generator.
8. Remove the strut tower brace.
9. Dismount and position aside the A/C compressor with the piping attached.
10. Dismount and position aside the power steering pump and reservoir tank with the piping attached.
11. Remove the upper and lower oil pan, and oil strainer.





12. Remove IVT control cover bolts in the order shown.
13. Remove the IVT control cover by cutting the sealant using Tool.
Tool number: KV10111100 (J-37228)
14. Pull chain guide between camshaft sprockets out through front cover.





15. Set the No.1 cylinder at TDC on the compression stroke with the following procedure:
a. Rotate the crankshaft pulley clockwise and align the mating marks to the timing indicator on the front cover.





b. At the same time, make sure that the mating marks on camshaft sprockets are lined up with the yellow links in the timing chain, as shown.
- If not, rotate crankshaft pulley one more turn to line up the mating marks to the yellow links, as shown.





16. Remove crankshaft pulley with the following procedure:
a. Hold the crankshaft pulley with a suitable tool, then loosen the crankshaft pulley mounting bolt, and pull the pulley out about 10 mm (0.39 inch). Remove the crankshaft pulley mounting bolt.





b. Attach a pulley puller in the M6 (0.24 in diameter) thread hole on crankshaft pulley, and remove crankshaft pulley.





17. Remove the front cover with the following procedure:
a. Loosen the front cover bolts in the order shown, and remove them.
b. Remove the front cover.

CAUTION: Be careful not to damage the mounting surface.

18. If the front oil seal needs to be replaced, lift it out with a screwdriver to remove it.





19. Remove timing chain with the following procedure:
a. Push in the tensioner plunger. Insert a stopper pin into the hole on the tensioner body to hold the chain tensioner.
- Use a wire of 0.5 mm (0.02 inch) diameter as a stopper pin.
b. Remove the chain tensioner.





c. Secure hexagonal part of the camshaft with a wrench and loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket for both camshafts.

CAUTION: Do not rotate the crankshaft or camshafts while the timing chain is removed. It can cause damage to the valve and piston.

20. Remove the chain slack guide, tension guide, timing chain and nil pump drive spacer.





21. Remove the timing chain tensioner for the balancer unit with the following procedure:
a. Lift the tensioner lever up, and release the ratchet claw.
b. Push tensioner sleeve in, and hold it.
c. Matching the hole on lever with the one on body, insert a stopper pin to secure tensioner sleeve.
d. Remove the timing chain tensioner for the balancer unit.
22. Remove timing chain for balancer unit and crankshaft sprocket.





23. Loosen balancer unit bolts in order shown and remove balancer unit.
- Use Torx socket (size E14)

CAUTION: Do not disassemble balancer unit.

INSPECTION AFTER REMOVAL
Timing Chain





Check the timing chain for cracks or serious wear. If a defect is detected, replace it.

Balancer Unit Mounting Bolt Outer Diameter





- Measure outer diameters (d1, d2) at the two positions shown in the figure.
- Measure d2 within the range A.
- If the value difference (d1 - d2) exceeds the limit (a dimension difference is large), replace it with a new one.
Limit: 0.15 mm (0.0059 inch) or more

INSTALLATION

NOTE: There may be two color variations of the link marks (link colors) on the timing chain. There are 26 links between the gold/yellow mating marks on the timing chain; and 64 links between the camshaft sprocket gold/yellow link and the crankshaft sprocket orange/blue link, on the timing chain side without the tensioner.

1. Make sure the crankshaft key points straight up.





2. Install the balancer unit and tighten the balancer unit bolts in five steps in the order shown.

CAUTION: When reusing a balancer unit bolt, check its outer diameter before installation. Refer to Balancer Unit Mounting Bolt Outer Diameter.

Step 1: 45.2 - 51.0 Nm (4.6 - 5.2 kg-m, 34 - 37 ft. lbs.)
Step 2: 90° - 95° degrees (Target: 90° degrees)
Step 3: 0 Nm (0 kg-m, 0 ft. lbs.) (loosen)
Step 4: 45.2 - 51.0 Nm (4.6 - 5.2 kg-m, 34 - 37 ft. lbs.)
Step 5: 90° - 95° degrees (Target: 90° degrees)





CAUTION: Check tightening angle with an angle wrench or a protractor. Do not make judgment by visual check alone.





3. Install the crankshaft sprocket and timing chain for the balancer unit.
- Make sure that the crankshaft sprocket is positioned with mating marks on the block and sprocket meeting at the top.
- Install it by lining up mating marks on each sprocket and timing chain.





4. Install timing chain tensioner for balancer unit.

NOTE: Chain guide and tensioner move freely with the caulking pin as the axle. Therefore, bolt hole position of the three points could be changed during removal. If points change, temporarily fix the two mounting bolts on the chain guide and move the tensioner to match the bolt holes.

- Be careful not to let mating marks of each sprocket and timing chain slip.
- After installation, make sure the mating marks have not slipped, then remove stopper pin and release tensioner.





5. Install timing chain and related parts.
- Install by lining up mating marks on each sprocket and timing chain as shown.

NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that of each sprocket for alignment.

CAUTION: For the above reason, after the mating marks are aligned, keep them aligned by holding them with a hand.

- Before and after installing chain tensioner, check again to make sure that mating marks have not slipped.
- After installing chain tensioner, remove stopper pin, and make sure the tensioner moves freely.
- To avoid skipped teeth, do not move crankshaft and camshaft until front cover is installed.





6. Install front oil seal to front cover.
- Using a drift of 56 mm (2.20 inch) diameter, press oil seal in until it is flush with front end surface of front cover.

CAUTION: Be careful not to cause damage to circumference of oil seal.





7. Install front cover as follows:
a. Install new O-rings to cylinder head and cylinder block.
b. Apply Genuine Silicone RTV Sealant or equivalent, to positions shown. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
c. Make sure the mating marks on the timing chain and each sprocket are still aligned. Then install the front cover.

CAUTION: Be careful not to damage the front oil seal during installation with the front end of the crankshaft.

d. Tighten front cover bolts in two steps in the order shown.
Front cover bolts: 12 - 14 Nm (1.3 - 1.4 kg-m, 9 - 10 ft. lbs.)

CAUTION: Wipe off any excess sealant leaking at the surface for installing the oil pan.

8. Install the chain guide between the camshaft sprockets.
9. Install IVT control cover as follows:
a. Install IVT control solenoid valves to IVT control cover.
b. Install new oil rings to the intake camshaft sprocket insertion points on IVT control backside cover.





c. Install new O-ring to front cover.





d. Apply Genuine Silicone RTV Sealant or equivalent, to positions shown.
- Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.





e. Tighten the IVT control cover bolts in the order shown.
IVT control cover bolts: 12 - 13 Nm (1.2 - 1.4 kg-m, 9 - 10 ft. lbs.)
10. Insert crankshaft pulley by aligning with crankshaft key.
- Tap its center with a plastic hammer to insert.
11. Tighten crankshaft pulley bolt.
- Secure crankshaft pulley with a pulley holder to tighten the bolt
- Perform angle tightening with the following procedure:
a. Apply new engine oil to threads and seat surfaces of bolt.
b. Tighten to initial specifications:
Crankshaft pulley bolt initial tightening: 37.3 - 47.1 Nm (3.8 - 4.8 kg-m, 28 - 34 ft. lbs.)





c. Apply a paint mark on the front cover, mating with any one of six easy to recognize stamp marks on bolt flange.
d. Turn crankshaft pulley bolt another 60° to 66° degrees [Target: 60° degrees].
- Check vertical mounting angle with movement of one stamp mark.
12. Installation of the remaining parts is in reverse order of removal.