Removal and Installation
TIMING CHAIN
Removal and Installation
REMOVAL
1.Release the fuel pressure. Testing and Inspection.
2.Disconnect the 12V battery cable from the negative terminal.
3.Remove engine cover. Exploded View.
4.Remove radiator reservoir tank. Exploded View.
5.Remove air duct and air cleaner case assembly (bank 1 and bank 2). Service and Repair.
6.Remove engine undercover, using a power tool.
7.Drain engine coolant from radiator. Draining Engine Coolant.
CAUTION:
- Perform this step when the engine is cold.
8.Remove radiator hose (upper and lower). Exploded View.
9.Drain engine oil. Draining.
CAUTION:
- Perform this step when the engine is cold.
10.Remove radiator cooling fan assembly. Exploded View.
11.Separate engine harnesses removing their brackets from front timing chain case.
12.Remove intake manifold collector. Exploded View.
13.Remove intake manifold. Exploded View.
14.Remove fuel sub tube mounting bolt. Exploded View.
15.Remove oil level gauge and oil level gauge guide.
16.Remove water outlet (front) and water piping. Exploded View.
17.Remove valve timing control covers (bank 1 and bank 2) and gasket as follows:
a.Disconnect valve timing control harness connector.
b.Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
Shaft is internally jointed with camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected.
c.Shaft is engaged with camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged.
18.Remove rocker covers (bank 1 and bank 2). Exploded View.
19.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 (with heater pipe bracket).
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.
- If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
20.Remove crankshaft pulley as follows:
a.Remove the plate of transmission joint (A) or (B) and turn the flywheel to a position where the notch (C) on the flywheel becomes visible.
b.Place a flat-blade screwdriver (A) in the notch of flywheel as shown in the figure and turn the crankshaft pulley in the loosening direction until it reaches the oil pan (upper).
CAUTION:
Since the notch is not deep enough, securely fix the flywheel with a flat-blade screwdriver.
c.After checking that the flywheel is securely fixed, turn the crankshaft pulley in the loosening direction to loosen crankshaft pulley bolt.
d.Loosen crankshaft pulley bolt and rotate bolt seating surface at
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.
e.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). Exploded View.
22.Loosen two mounting bolts in front of oil pan (upper), using a power tool in reverse order as shown in the figure.
23.Remove front timing chain case as follows:
a.Loosen mounting bolts in reverse order as shown in the figure.
b.Insert a suitable tool (A) into the notch at the top of front timing chain case as shown.
c.Pry off case by moving the suitable tool as shown.
- Use the seal cutter [SST: KV10111100] to cut liquid gasket for removal.
CAUTION:
- Never use a screwdriver or something similar. Failure to do this may cause damage to the parts.
- After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
24.Remove front oil seal from front timing chain case using a suitable tool.
- Use a screwdriver for removal.
CAUTION:
Never damage front timing chain case.
25.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 upper 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).
26.Remove internal chain guide (1) and slack guide (2).
27.Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain tensioner (primary), never turn crankshaft and camshaft separately, or valves will strike the piston heads.
28.Remove timing chain (secondary) and camshaft sprockets as follows:
a.Attach suitable stopper pin (2) to the timing chain tensioners (secondary) (1).
NOTE:
- Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin.
- For removal of timing chain tensioners (secondary), refer to
Exploded View. [Removing camshaft bracket (No. 1)
is required.]
b.Remove camshaft sprocket mounting bolts (INT and EXH).
- Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts.
c.Remove timing chain (secondary) together with camshaft sprockets.
CAUTION:
- Never loosen the mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
- Never disassemble. [Never loosen bolts (A) and (B) as shown in the figure.]
29.Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a.Remove camshaft brackets (No. 1). Exploded View.
b.Remove timing chain tensioners (secondary) with a stopper pin attached.
30.Use a 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:
Never allow gasket fragments to enter oil pan.
31.Remove old liquid gasket from bolt hole and thread.
INSTALLATION
NOTE:
The below figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.
1.Install timing chain tensioners (secondary) to cylinder head as follows if removed. Exploded View.
2.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 noses, 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.
3.Install timing chains (secondary) and camshaft sprockets as follows:
CAUTION:
Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.
a.Push plunger of timing chain tensioner (secondary) and keep it pressed in with a stopper pin (A).
b.Install timing chains (secondary) and camshaft sprockets.
- Align the matching marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets (punched), and install them.
NOTE:
- Figure shows bank 1 (rear view).
- Matching marks for camshaft sprockets are on the back side of camshaft sprockets (secondary).
- There are two types of matching 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 camshafts with the groove or dowel hole on sprockets, and install them.
- On the intake side, align dowel pin on camshaft front end with pin groove on the back side of camshaft sprocket, and install them.
- On the exhaust side, align dowel pin on camshaft front end with pin hole on camshaft sprocket, and install them.
- In case that positions of each matching mark and each dowel pin are not fit on matching 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 next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.
- Check the matching marks (punched) (D) on each camshaft sprocket are positioned on the matching marks (orange link)
(C) on timing chain (secondary).
NOTE:
Matching mark (punched) in the figure is for checking loose at this step.
c.After confirming the matching marks are aligned, tighten camshaft sprocket mounting bolts.
- Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts.
d.Pull stopper pins (2) out from timing chain tensioners (secondary) (1).
4.Install timing chain (primary) as follows:
a.Install crankshaft sprocket (1).
- Check the matching marks on crankshaft sprocket face the front of the engine.
b.Install timing chain (primary).
- Install timing chain (primary) so the matching mark (punched)
(B) on camshaft sprocket (INT) (1) is aligned with the yellow link (A) on timing chain, while the matching mark (notched) (C)
on crankshaft sprocket (2) is aligned with the orange link (D)
one on timing chain, as shown in the figure.
- When it is difficult to align matching marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the matching marks.
- During alignment, be careful to prevent dislocation of matching mark alignments of timing chains (secondary).
5.Install internal chain guide (1) and slack guide (2).
CAUTION:
Never overtighten slack guide (1) mounting bolts (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolts are tightened to the specification.
6.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 plunger stopper 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.
7.Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.
8.Install new O-rings (1) on rear timing chain case.
9.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).
- Install it so that each seal lip is oriented as shown in the figure.
- Using a 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.
10.Install front timing chain case as follows:
- Check O-rings stay in place during installation to rear timing chain case.
a.Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.
b.Apply liquid gasket to top surface of oil pan (upper) as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.
c.Assemble front timing chain case.
CAUTION:
- Never damage front oil seal by interference with front end of crankshaft.
- Attaching should be done within 5 minutes after liquid gasket application.
d.Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
e.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.
f.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).
g.Install two mounting bolts in front of oil pan (upper) in numerical order shown in the figure.
Tightening torque: Exploded View.
11.Install valve timing control covers (bank 1 and bank 2) as follows:
a.Install new seal rings (1) in shaft grooves.
CAUTION:
When replacing seal ring, replace all rings with new one.
b.Install valve timing control cover with new gasket to front timing chain case.
CAUTION:
- Align the center of both shaft holes of the shaft and the camshaft sprocket, and then insert them.
- Never drop the seal ring from the shaft groove.
c.Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with holes to install valve timing control covers.
d.Tighten mounting bolts in numerical order as shown in the figure.
Tightening torque: Exploded View.
- After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
12.Install oil pan (lower). Exploded View.
13.Install rocker covers (bank 1 and bank 2). Exploded View.
14.Install crankshaft pulley as follows:
a.Fix the crankshaft in the same way as in removal.
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.
d.Place a matching mark (A) on crankshaft pulley (2) aligning with the matching mark (C) of crankshaft pulley bolt (1). Tighten the bolt 90 degrees (one marks) (b).
e.Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
15.For the following operations, perform steps in the reverse order of removal.