Removal and Installation
TIMING CHAIN
Removal and Installation
CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
REMOVAL
1. Remove front RH wheel. Refer to Rotation.
2. Remove front fender protector (RH). Refer to Removal and Installation.
3. Drain engine oil. Refer to .
CAUTION:
Perform this step when engine is cold.
4. Remove the following parts.
- Rocker cover: Refer to Component.
- Drive belt: Refer to Removal and Installation.
- Water pump pulley: Refer to Component.
- 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). Refer to Overhaul.
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)
Arrow Indicates 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 crankshaft 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.
Tool number : KV10109300 ( - )
8. Attach Tool (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley.
Tool number : KV11103000 ( - )
9. Remove oil pan (lower). Refer to Component.
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
Arrow Indicates Engine front
CAUTION:
- Secure the oil pump shaft with the WAF part (A).
- 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 (orange 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
Arrow Indicates Engine front
CAUTION:
- Secure the oil pump shaft with the WAF part (A).
- 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 (orange 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. Install front oil seal so that each seal lip is oriented as shown.
A : Dust seal lip
B : Oil seal lip
White Arrow Indicates Engine front
Dark Arrow Indicates Engine rear
- Install front oil seal (2) using a suitable tool with outer diameter 57 mm (2.24 in) and inner diameter 45 mm (1.77 in) (A) to the dimension shown.
1 : Front cover
Arrow Indicates Engine front
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 are aligned properly.
13. Apply the sealant without breaks to the specified location using Tool.
Use Genuine Silicone RTV Sealant or equivalent. Refer to Fluid Type Specifications.
Tool number WS39930000 ( - )
A : Liquid gasket application area
B : Liquid gasket
Arrow Indicates :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 two stages to specified torque in numerical order as shown.
CAUTION:
- Attaching should be done within 5 minutes after liquid gasket application.
- Be sure to wipe off any excessive liquid gasket leaking.
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. Install crankshaft pulley using the following procedure.
a. 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.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
c. Secure crankshaft pulley (1) using Tool (A).
Tool Number : KV10109300 ( - )
d. Tighten crankshaft pulley bolt in two steps.
- For angle tightening, 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).
- Turn 60 degrees clockwise (angle tightening).
- Check the tightening angle with movement of one angle mark.
e. Make sure that crankshaft rotates clockwise smoothly.
17. Installation of the remaining components is in the reverse order of removal.