Removal And Installation

TIMING CHAIN

Removal and Installation

CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Disconnect the battery negative terminal. Removal and Replacement.
2.Drain engine oil. Removal and Replacement.

CAUTION:
Perform this step when engine is cold.
3.Partially drain engine coolant from the radiator. Changing Engine Coolant.
4.Remove front RH wheel. Adjustment.
5.Remove front fender protector (RH). Removal And Installation.
6.Remove the following parts.
- Rocker cover: Component.
- Drive belt: Removal And Installation.
- Water pump pulley: Component.
- Ground cable (between engine bracket (RH) and radiator core support)
7.Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH). Component.
8.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.

b.At the same time, make sure that the cam noses of the No.1 cylinder are located (black arrow) as shown.

- If not, rotate crankshaft pulley one revolution (360 degrees)
and align as shown.

9.Hold crankshaft pulley (1) using Tool (A), while loosening crankshaft pulley bolt using suitable tool, and locate bolt seating surface at 10 mm (0.39 in) from its original position.

CAUTION:
Do not remove the crankshaft pulley bolt as it will be used as a supporting point for the pulley puller.

Tool number : KV-10109300 ( - )

10.Attach Tool (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley.
Tool number: KV-11103000 ( - )
11.Remove oil pan (lower). Component.

CAUTION:
Do not use an impact or other power tool to remove the engine oil pump sprocket bolt. If an impact or other power tool is used to remove the engine oil pump sprocket bolt, the crankshaft sprocket may break.
NOTE:
When crankshaft sprocket, oil pump sprocket and other related parts are not removed, this step is unnecessary.
12.Remove intake valve timing control solenoid valve.
13.Remove drive belt auto-tensioner.

14.Loosen bolts in reverse order as shown.

15.Cut liquid gasket by prying the position (black arrow) 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.
16.Remove front oil seal from front cover.
- Lift up front oil seal using a suitable tool.

CAUTION:
Be careful not to damage front cover.
17.Push in timing chain tensioner plunger.

18.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.
19.Remove timing chain tensioner (1).

20.Remove timing chain slack guide (2), timing chain tension guide (3) and timing chain (1).

CAUTION:
Do not rotate each crankshaft and camshaft individually while timing chain is removed. It causes interference between valve and piston.

21.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.
22.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.
23.Remove timing chain tensioner (for oil pump), if necessary.
24.Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them.

CAUTION:
- Secure the oil pump shaft with the WAF part (A).
- Do not loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
- Do not use an impact or other power tool to remove the engine oil pump sprocket bolt. If an impact or other power tool is used to remove the engine oil pump sprocket bolt, the crankshaft sprocket may break.
25.Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set, if necessary.
26.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.

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).

- 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.

CAUTION:
Do not use an impact or other power tool to remove the engine oil pump sprocket bolt. If an impact or other power tool is used to remove the engine oil pump sprocket bolt, the crankshaft sprocket may break.

4.Hold the WAF part of oil pump shaft (A), and then tighten the oil pump sprocket bolt.

5.Install chain tensioner (for oil pump) (1).
1.Secure the plunger at the most compressed position using a stopper pin (A), and then install it.
2.Securely pull out (black arrow) 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.

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).

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.

- 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.

Within 0.3 mm (0.012 in) toward engine front
Within 0.5 mm (0.020 in) toward engine rear

CAUTION:
- Do not reuse front oil seal.
- Be careful not to damage front cover and crankshaft.
- Press-fit oil seal straight to avoid causing burrs or tilting.
- Do not touch grease applied onto oil seal lip.
12.Install new O-ring to cylinder block.

CAUTION:
- Do not reuse O-ring.
- 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 Recommended Chemical Products And Sealants.
Tool number WS-39930000 (-)

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:
- Installation 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.

16.Install crankshaft pulley using the following procedure.
a.Install crankshaft pulley.

CAUTION:
- Do not 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 : KV-10109300 ( - )
d.Tighten crankshaft pulley bolt in two steps.

Step 1: 29.4 Nm (3.0 kg-m, 22 ft-lb)
Step 2: 60� clockwise

- 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.