Timing Chain: Service and Repair
Removal and InstallationEM-37 Component:
CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
REMOVAL
1. Remove front RH wheel.
2. Remove front fender protector (RH).
3. Drain engine oil.
NOTE:
Perform this step when engine is cold.
4. Remove the following parts.
^ Rocker cover
^ Drive belt
^ Water pump pulley
^ Ground cable (between engine bracket (RH) and radiator core support)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH).
6. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.
C: White paint mark (Not use for service)
b. At the same time, make sure that the cam noses of the No.1 cylinder are located (<---) as shown.
1: Camshaft (INT)
2: Camshaft (EXH)
<---: Engine front
^ If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
7. Hold crankshaft pulley (1) using suitable tool (A) loosen crank shaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as it will be used as a supporting point for the pulley puller.
8. Attach a pulley puller (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley.
Tool number: KV11103000 ( - )
9. Remove oil pan (lower).
NOTE:
When crankshaft sprocket, oil pump sprocket and other related parts are not removed, this step is unnecessary.
10. Remove intake valve timing control solenoid valve.
11. Remove drive belt auto-tensioner.
12. Loosen bolts in reverse order as shown.
13. Cut liquid gasket by prying the position (<---) shown, and then remove the front cover.
CAUTION:
^ Be careful not to damage the mating surface.
^ A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
14. Remove front oil seal from front cover.
^ Lift up front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front cover.
15. Push in timing chain tensioner plunger.
16. Insert a stopper pin (A) into the body hole to retain the plunger in collapsed position.
NOTE:
Use approximately 1.5 mm (0.059 in) diameter. hard metal pin as a stopper pin.
17. Remove timing chain tensioner (1).
18. Remove timing chain slack guide (2), timing chain tension guide (3) and timing chain (1).
CAUTION:
Never rotate each crankshaft and camshaft individually while timing chain is removed. It causes interference between valve and piston.
19. Press stopper tab (A) in the direction shown to push the timing chain slack guide (B) toward timing chain tensioner (for oil pump) (1).
^ The slack guide (B) is released by pressing the stopper tab (A). As a result, the slack guide (B) can be moved.
20. Insert stopper pin (D) into tensioner body hole (C) to secure timing chain slack guide (B).
NOTE:
Use a hard metal pin with a diameter of approximately 1.2 mm (0.047 in) as a stopper pin.
21. Remove timing chain tensioner (for oil pump).
22. Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them.
1: Oil pan (upper)
2: Oil pump
<---: Engine front
CAUTION:
^ Secure the oil pump shaft with the WAF part.
^ Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
23. Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set.
24. Remove timing chain tension guide (front cover side) from front cover if necessary.
INSPECTION AFTER REMOVAL
Timing Chain
^ Check timing chain and oil pump drive chain for cracks (A) and any excessive wear (B) at the roller links of timing chain.
^ Replace timing chain and/or oil pump drive chain if necessary.
INSTALLATION
NOTE:
The figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.
1. Make sure that crankshaft key points are aligned.
1: Timing chain
2: Camshaft sprocket (EXH)
3: Timing chain slack guide
4: Timing chain tensioner
5: Oil pump sprocket
6: Oil pump drive chain
7: Chain tensioner (for oil pump)
8: Crankshaft sprocket
9: Timing chain tension guide
10: Camshaft sprocket (INT)
A: Matching mark (dark blue link)
B: Matching mark (stamping)
C: Crankshaft key position (straight up)
D: Matching mark (gold link)
E: Matching mark (orange link)
F: Matching mark (outer groove*)
NOTE:
*: There are two outer grooves in camshaft sprocket (INT). The wider one is a matching mark.
2. If the timing chain tension guide (front cover side) is removed, install it to the front cover.
CAUTION:
Check the joint condition by sound or feeling.
3. Install crankshaft sprocket (2), oil pump sprocket (3) and oil pump drive chain (1).
A: Matching mark (stamping)
B: Matching mark (orange link)
C: Matching mark (dark blue link)
^ Install it by aligning matching marks on each sprocket and oil pump drive chain.
^ If these matching marks are not aligned, rotate the oil pump shaft slightly to correct the position.
CAUTION:
Check matching mark position of each sprocket after installing the oil pump drive chain.
4. Hold the WAF part of oil pump shaft (A), and then tighten the oil pump sprocket bolt.
1: Oil pan (upper)
2: Oil pump
<---: Engine front
CAUTION:
^ Secure the oil pump shaft with the WAF part.
^ Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
5. Install chain tensioner (for oil pump) (1).
1. Fix the plunger at the most compressed position using a stopper pin (A), and then install it.
2. Securely pull out (<---) the stopper pin after installing the chain tensioner (for oil pump).
3. Check matching mark position of oil pump drive chain and each sprocket again.
6. Align the matching marks of each sprocket with the matching marks of timing chain.
1: Camshaft sprocket (EXH)
2: Camshaft sprocket (INT)
3: Timing chain
A: Matching mark (dark blue link)
B: Matching mark (stamping)
C: Matching mark (outer groove*)
D: Matching mark (gold link)
E: Matching mark (stamping)
NOTE:
*: There are 2 outer grooves in camshaft sprocket (INT). The wider one is a matching mark.
^ If these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion to correct the position.
CAUTION:
Check matching mark position of each sprocket and timing chain again after installing the timing chain.
7. Install the timing chain tension guide (3) and the timing chain slack guide (2).
1: Timing chain
8. Install timing chain tensioner (1).
1. Fix the plunger at the most compressed position using a stopper pin (A), and then install it.
2. Securely pull out the stopper pin after installing the timing chain tensioner.
9. Check matching mark position of timing chain and each sprocket again.
10. Apply new engine oil to new front oil seal joint surface.
11. Using a suitable tool install front oil seal so that each seal lip is oriented as shown.
A: Dust seal lip
B: Oil seal lip
<---: Engine front
<---: Engine rear
^ Press-fit front oil seal until it is flush with front end surface of front cover as shown below with a suitable tool.
Within 0.3 mm (0.012 in) toward engine front
Within 0.5 mm (0.020 in) toward engine rear
CAUTION:
^ Be careful not to damage front cover and crankshaft.
^ Press-fit oil seal straight to avoid causing burrs or tilting.
^ Never touch grease applied onto oil seal lip.
12. Install new O-ring to cylinder block.
CAUTION:
Be sure O-rings a aligned properly.
13. Apply the sealant without breaks to the specified location using Tool.
Use Genuine Silicone RTV Sealant or equivalent.
Tool number WS39930000 ( - )
A: Liquid gasket application area
<---: Engine outside
14. Make sure that matching marks of timing chain and each sprocket are still aligned.
CAUTION:
^ Make sure O-ring on cylinder block is correctly installed.
^ Be careful not to damage front oil seal by interference with front end of crankshaft.
15. Install front cover, and tighten bolts in numerical order as shown.
CAUTION:
Attaching should be done within 5 minutes after liquid gasket application.
NOTE:
Installation position of bolts is as shown.
M6 bolts: No. 1
M10 bolts: No. 6, 7, 10, 11, 14
M12 bolts: No. 2, 4, 8, 12
M8 bolts: Except the above
16. Tighten all bolts are in two stages to specified torque in numerical order as shown.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking.
17. Install crankshaft pulley.
CAUTION:
^ Never damage front oil seal lip section.
^ If needed use a plastic hammer, tap on its center portion (not circumference) to seat crankshaft pulley.
18. Secure crankshaft pulley (1) using Tool (A).
Tool Number (A): KV10109300 ( - )
19. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
20. Tighten crankshaft pulley bolt in three steps.
Step 1: 68.6 Nm (7.0 kg-m, 51 ft-lb)
Step 2: 0 Nm (0 kg-m, 0 ft-lb)
Step 3: 29.4 Nm (3.0 kg-m, 22 ft-lb)
21. Put a paint mark (B) on crankshaft pulley (2), matching with any one of six easy to recognize angle marks (A) on crankshaft pulley bolt flange (1).
22. Turn another 60 degrees clockwise (angle tightening) using Tool.
^ Check the tightening angle with movement of one angle mark.
Tool number: KV10112100 (BT-8653-A)
23. Make sure that crankshaft rotates clockwise smoothly.
24. Installation of the remaining components is in the reverse order of removal.