Timing Cover: Service and Repair
FRONT TIMING CHAIN CASE
Removal and Installation
NOTE:
- This section describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle.
- When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in the reverse order of removal. Component.
- Component for component parts location.
REMOVAL
1. Remove engine cover with power tool. Removal and Installation.
2. Remove front and rear undercover with power tool.
3. Release the fuel pressure. Testing and Inspection.
4. Disconnect the battery cable from the negative terminal.
5. Drain engine oil. Removal and Replacement.
CAUTION:
- Perform this step when engine is cold.
- Never spill engine oil on drive belt.
6. Drain engine coolant from radiator. Changing Engine Coolant.
CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belt.
7. Remove radiator cooling fan assembly. Component.
8. Separate engine harnesses removing their brackets from front timing chain case.
9. Remove drive belt. Procedures Adjustments Removal and Installation.
10. Remove intake manifold collector. Component Removal and Installation.
11. Remove harness bracket and fuel sub tube mounting bolt on front timing chain case.
12. Remove oil level gauge and guide.
13. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside. Service and Repair.
14. Remove power steering oil pump bracket. Component.
15. Remove alternator. Removal and Installation.
16. Remove water outlet and water piping. Component.
17. Remove left and right valve timing control covers with the following procedure.
a. Disconnect valve timing control harness connector.
b. Loosen mounting bolts in reverse order as shown in the figure.
A: Bank 1
B: Bank 2
C: Dowel pin hole
c. 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)
18. Remove rocker covers (bank 1 and bank 2). Component Removal and Installation.
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
19. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE:
When timing chain is not removed/installed, this step is not required.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
Black arrow: Timing mark (grooved 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.
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed. To check that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets. Component,
"Component".
20. 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 (upper)
2: Drive plate
White arrow: Vehicle front
b. Loosen crankshaft pulley bolt and locate bolt seating surface as
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.
21. Remove oil pan (lower). Component Removal and Installation.
22. Loosen two mounting bolts in front of oil pan (upper) in reverse order as shown in the figure.
White arrow: Engine front
23. 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 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.
24. Remove O-ring (1) from rear timing chain case.
A: Bank 1
B: Bank 2
25. 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.
26. Remove timing chain and related parts. Component.
27. Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces.
CAUTION:
Be careful not to allow gasket fragments to enter oil pan.
- Remove old liquid gasket from bolt hole and thread.
A: Remove sticking old liquid gasket
B: Bolt hole
INSTALLATION
1. Install timing chain and related parts. Component.
2. Install new O-ring (1) on rear timing chain case.
A: Bank 1
B: Bank 2
3. 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.
4. Install new front oil seal on the 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 [outer diameter: 60 mm (2.36 in)] (A), 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.
5. 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.
- Apply liquid gasket with tube presser (commercial service tool) to top surface of oil pan (upper) as shown in the figure.
A: [diameter]4.0 - 5.0 mm (0.157 - 0.197 in)
Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.
b. Assemble front timing chain case as follows:
Fit lower end of front timing chain case (1) tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely.
2: Oil pan (upper)
3: Cylinder block
White arrow: Engine front
CAUTION:
- Be careful not to damage front oil seal by interference with front end of crankshaft.
- Attaching should be done within 5 minutes after liquid gasket application.
c. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
d. 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.
M10 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)
e. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
6. Install two mounting bolts in front of oil pan (upper) in numerical order as shown in the figure.
White arrow: Engine front
Torque: 17.2 Nm (1.8 kg-m, 13 ft-lb)
7. Install oil pan (lower). Component Removal and Installation.
8. 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 ring, 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) with new gasket 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
CAUTION:
Completely tighten the mounting bolts with the seat surface of valve timing control cover contacting with front timing chain case.
Torque: 11.3 Nm (1.2 kg-m, 8 ft-lb)
- After all bolt are tightened, tighten No. 1 bolt to the specified torque again.
9. 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.
10. 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.
11. For the following operations, perform steps in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluid 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.
- 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 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.
