Removal and Installation
TIMING CHAIN
Removal and Installation
NOTE:
- This section describes procedures for removing/installing front timing chain case and timing chain related parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul, etc.
- To remove/install front timing chain case, timing chain, and its related parts without removing oil pan (upper), Service and Repair.
REMOVAL
1. Remove engine assembly from the vehicle, and separate front suspension member and transmission from engine. (2WD models) or (AWD models).
2. Lift the engine with hoist and mount it onto widely use engine stand. Disassembly and Assembly.
3. Remove intake manifold collector. Component Removal and Installation.
4. Remove power steering oil pump bracket. Component.
5. Remove alternator. Removal and Installation.
6. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
7. Remove left and right valve timing control covers (including magnet retarder and cover) with the following procedure.
a. Loosen mounting bolts in reverse order as shown in the figure.
A: Bank 1
B: Bank 2
C: Dowel pin hole
b. Shaft is engaged with intake side camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged.
- The mating surface of magnet retarder (2) may be fitted with the exhaust side camshaft sprocket via the engine oil. Open valve timing control cover (1) carefully.
- If the mating surface of magnet retarder is fitted with the camshaft sprocket, open the cover within the range that the load is not applied to the harness. And then, remove it so as to prevent magnet retarder from dropping.
CAUTION:
- Be careful not to damage magnet retarder.
- When carrying valve timing control cover, face the magnet retarder side up to prevent the cover from falling from magnet retarder.
- Never remove magnet retarder from valve timing control cover. (Disassembly prohibited parts)
8. Remove rocker covers (bank 1and bank 2). Component Removal and Installation.
9. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
Black arrow: Timing mark (grooved line without color)
b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of bank 1) are located as shown in the figure.
White arrow: Engine front
- If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
10. Remove crankshaft pulley as follows:
a. Remove rear cover plate and set ring gear stopper [SST:
KV10118600 (J-48641)] (A) as shown in the figure.
1: Oil pan
2: Drive plate
White arrow: Vehicle front
b. Loosen crankshaft pulley bolt and rotate bolt seating surface at
10 mm (0.39 in) from its original position.
1: Crankshaft pulley
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
11. Remove oil pans (upper and lower). Component Removal and Installation.
12. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Insert suitable tool (A) into the notch at the top of the front timing chain case as shown.
c. Pry off case by moving the tool as shown.
- Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
CAUTION:
- Never use screwdriver or something similar.
- After removal, handle front timing chain case carefully so it never tilt, cant, or warp under a load.
13. Remove O-ring (1) from rear timing chain case.
A: Bank 1
B: Bank 2
14. Remove front oil seal from front timing chain case using suitable tool.
- Use screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
15. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (A).
b. Loosen upper mounting bolt (B) slowly, and then turn timing chain tensioner (primary) (1) on the mounting bolt so that plunger (C) is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain tensioner (primary).
16. Remove internal chain guide (1) and slack guide (2).
17. Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves will strike the piston heads.
18. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin (2) to the right and left timing chain tensioners (secondary) (1).
A: Bank 1
B: Bank 2
NOTE:
- Use approximately 0.5 mm (0.020 in) dia. hard metal pin as a stopper pin.
- For removal of timing chain tensioner (secondary), Component Removal and Installation. [Removing camshaft bracket (No. 1) is required.]
b. Remove intake and exhaust camshaft sprocket bolts.
- Secure the hexagonal portion of camshaft using wrench to loosen mounting bolts.
CAUTION:
Never loosen mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
c. Remove timing chain (secondary) together with camshaft sprockets.
CAUTION:
- Handle carefully to avoid any shock to camshaft sprocket.
- Never disassemble. [Never loosen bolts (A) and (B) as shown in the figure.]
19. Remove water pump. Component.
20. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in the figure.
b. Cut liquid gasket using seal cutter [SST: KV10111100 (J37228)]
and remove rear timing chain case.
CAUTION:
- Never remove plate metal cover (1) of oil passage.
- After removal, handle rear timing chain case carefully so it never tilt, cant, or warp under a load.
21. Remove O-rings (1) from cylinder block.
White arrow: Engine front
22. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Removal and Installation.
b. Remove timing chain tensioners (secondary) with stopper pin
(A) attached.
23. Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and opposite mating surfaces.
- Remove old liquid gasket from bolt hole and thread.
A: Remove sticking old liquid gasket
B: Bolt hole
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks (A) and any excessive wear (B) at link plates and roller links of timing chain. Replace timing chain if necessary.
INSTALLATION
NOTE:
- The below figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.
- In this figure, the drum of exhaust side camshaft sprocket has been omitted.
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Removal and Installation.
a. Install timing chain tensioners (secondary) with stopper pin attached and new O-ring.
b. Install camshaft brackets (No. 1). Removal and Installation.
2. Measure difference in levels between front end faces of camshaft bracket (No. 1) and cylinder head.
Standard: -0.14 to 0.14 mm (-0.0055 to 0.0055 in)
- Measure two positions (Both intake and exhaust side) for a single bank.
- If the measured value is out of the standard, reinstall camshaft bracket (No. 1).
3. Install rear timing chain case as follows:
a. Install new O-rings (1) onto cylinder block.
White arrow: Engine front
b. Apply liquid gasket with tube presser (commercial service tool) to rear timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.
CAUTION:
- For "A" in the figure, completely wipe out liquid gasket extended on a portion touching at engine coolant.
- Apply liquid gasket on installation position of water pump and cylinder head very completely.
- Key to Symbols for symbols in the figure.
c. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block and install rear timing chain case.
- Check O-rings stay in place during installation to cylinder block.
d. Tighten mounting bolts in numerical order as shown in the figure.
- There are two types of mounting bolts. Refer to the following for locating bolts.
Bolt length: Bolt position
20 mm (0.79 in): 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in): 4, 5, 11, 12, 13
Torque: 12.7 Nm (1.3 kg-m, 9 ft-lb)
16 mm (0.63 in): Except the above
Torque: 15.0 Nm (1.5 kg-m, 11 ft-lb)
e. After all bolts are tightened, retighten them to the specified in numerical order shown in the figure.
- If liquid gasket protrudes, wipe it off immediately.
f. After installing rear timing chain case, check the surface height difference between following parts on oil pan (upper) mounting surface.
1: Rear timing chain case
2: Lower cylinder block
Standard
Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.0094 to 0.0055 in)
- If not within standard, repeat the installation procedure.
4. Install water pump with new O-rings. Component.
5. Check that dowel pin (A) and crankshaft key (1) are located as shown in the figure. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
Camshaft dowel pin: At cylinder head upper face side in each bank.
Crankshaft key: At cylinder head side of bank 1.
6. Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
- When replacing camshaft sprocket (EXH), replace valve timing control cover (including magnet retarder and cover).
- Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin (A).
b. Install timing chains (secondary) and camshaft sprockets.
NOTE:
Figure shows bank 1 (rear view).
A: Camshaft sprocket (INT) back face
B: Colored link
C: Mating mark (circle)
D: Mating mark (oval)
E: Dowel groove
F: Mating mark (2 oval)
G: Camshaft sprocket (EXH) back face
H: Mating mark (2 circle)
I: Dowel pin hole
J: Timing chain (secondary)
- Align the mating marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets
(punched), and install them.
NOTE:
- Mating marks for intake camshaft sprocket are on the back side of camshaft sprocket (secondary).
- There are two types of mating marks, circle and oval types.
They should be used for the bank 1 and bank 2, respectively.
Bank 1: Use circle type
Bank 2: Use oval type
- Align dowel pin hole on the small diameter side of the camshaft front end with dowel pin on the back side of camshaft sprockets, and install them.
- In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
- Mounting bolts for camshaft sprockets must be tightened in the step "d". Tightening them by hand is enough to prevent the dislocation of dowel pins.
c. Check that timing chain (secondary) is not loose from each camshaft sprocket.
- Check the mating marks (punched) (D) on each camshaft sprocket are positioned on the mating marks (orange link) (C) on timing chain (secondary).
A: Intake side
B: Exhaust side
NOTE:
Mating mark (punched) in the figure is for checking loose at this step.
d. Tighten camshaft sprocket mounting bolts.
- Secure camshaft using wrench at the hexagonal portion to tighten mounting bolts.
e. Pull stopper pins (2) out from timing chain tensioners (secondary) (1).
A: Bank 1
B: Bank 2
7. Install timing chain (primary) as follows:
a. Install crankshaft sprocket (1).
A: Crankshaft side
B: Engine front
C: Mating mark (Front side)
- Check the mating marks on crankshaft sprocket face the front of engine.
b. Install timing chain (primary).
- Install timing chain (primary) so the mating mark (punched) (B) on camshaft sprocket (INT) (1) is aligned with the yellow link
(A) on timing chain, while the mating mark (notched) (C) on crankshaft sprocket (2) is aligned with the orange link (D) on timing chain, as shown in the figure.
3: Water pump
- When it is difficult to align mating marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the mating marks.
- During alignment, be careful to prevent dislocation of mating mark alignments of timing chains (secondary).
8. Install internal chain guide (1) and slack guide (2).
CAUTION:
Never over tighten slack guide mounting bolts (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolts are tightened to specification.
1: Slack guide
3: Cylinder block
9. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B).
- The lever parts and the tab are synchronized. Therefore, the plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
e. Install timing chain tensioner (primary) (1).
- Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary).
f. Pull out stopper pin (A) after installing, and then release plunger.
10. Check again that the mating marks on sprockets and timing chain have not slipped out of alignment.
11. Install new O-ring (1) on rear timing chain case.
A: Bank 1
B: Bank 2
12. Hammer dowel pins (right and left) (A) into front timing chain case (1) up to a point close to taper in order to shorten protrusion length.
13. Install new front oil seal on front timing chain case.
- Apply new engine oil to both oil seal lip (A) and dust seal lip
(B).
White arrow: Engine inside
Black arrow: Engine outside
- Install it so that each seal lip is oriented as shown in the figure.
- Using suitable drift (1), press-fit oil seal until it becomes flush with front timing chain case end face.
- Check the garter spring is in position and seal lip is not inverted.
14. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front timing chain case back side as shown in the figure.
B: Protrusion
c: [diameter]3.4 - 4.4 mm (0.134 - 0.173 in)
d: [diameter]2.6 - 3.6 mm (0.102 - 0.142 in)
e: 4.0 - 5.6 mm (0.157 - 0.220 in)
Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.
NOTE:
Apply liquid gasket, start and end up application at the portions
(A) shown in the figure.
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
- There are two types of mounting bolts. Refer to the following for locating bolts.
M8 bolts: 1, 2, 3, 4, 5, 6, 7
Torque: 55.0 Nm (5.6 kg-m, 41 ft-lb)
M6 bolts: Except the above
Torque: 12.7 Nm (1.3 kg-m, 9 ft-lb)
d. After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).
e. After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface.
1: Front timing chain case
2: Rear timing chain case
3: Lower cylinder block
Standard
Front timing chain case to rear timing chain case: -0.24 to 0.14 mm (-0.0094 to 0.0055 in)
- If not within standard, repeat the installation procedure.
15. Install right and left valve timing control covers as follows:
a. Install new seal rings (1) in shaft grooves.
A: Bank 2
CAUTION:
When replacing seal rings, replace all rings with new one.
b. To check the joint between dowel pins and dowel pin holes, check the looseness in the axle direction by pushing the mating surface of magnet retarder (A) at several places and the circumferential looseness (between dowel pins and dowel pin holes) by twisting in the circumferential direction.
B: Moves slightly
C: Not shaken
CAUTION:
Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose.
c. Install valve timing control cover (1) to front timing chain case.
2: Magnet retarder
CAUTION:
- Never face the magnet retarder side down to prevent magnet retarder from dropping.
- Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign materials.
- Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then insert them.
- Be careful not to drop the seal ring from the shaft groove.
- When setting the valve timing control cover in position by hand, if valve timing control cover is not contacting with the front timing chain case, the dowel pin of magnet retarder may not be aligned with the dowel pin holes of cover. In this case, return to step "b".
d. Tighten mounting bolts in numerical order as shown in the figure.
A: Bank 1
B: Bank 2
C: Dowel pin hole
Torque: 11.3 Nm (1.2 kg-m, 8 ft-lb)
CAUTION:
Completely tighten the mounting bolts with the seat surface of valve timing control cover contacting with front timing chain case.
- After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
16. Install oil pans (upper and lower). Component Removal and Installation.
17. Install rocker covers (bank 1 and bank 2). Component Removal and Installation.
18. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10118600 (J-48641)].
b. Install crankshaft pulley, taking care not to damage front oil seal.
- When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
c. Tighten crankshaft pulley bolt.
Torque: 44.1 Nm (4.5 kg-m, 33 ft-lb)
d. Tighten the bolt 90 degrees (one mark) (b).
- Place a matching mark (A) on crankshaft pulley (2) aligning with the matching (C) of crankshaft pulley bolt (1).
e. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
19. Install power steering oil pump bracket and idler pulley bracket as follows:
a. Tighten mounting bolts in numerical order as shown in the figure. (temporarily)
1: Idler pulley bracket
2: Power steering oil pump bracket
3: Crankshaft pulley
A: Engine front side
B: Engine right side
White arrow: Engine front
b. Tighten mounting bolts to specified torque in numerical order as shown in the figure.
20. For the following operations, perform steps in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Maintenance.
- 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/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 check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
- Bleed air from lines and hoses of applicable lines, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
