Part 1

TIMING CHAIN

Removal and Installation


REMOVAL

1.Release the fuel pressure. For USA and Canada.
2.Disconnect the battery cable from the negative terminal.
3.Remove engine cover with power tool. Exploded View.
4.Remove radiator reservoir tank. Exploded View.
5.Remove air duct and air cleaner case assembly (RH and LH). Exploded View.
6.Remove engine undercover with power tool.
7.Drain engine coolant from radiator. Draining Engine Coolant.

CAUTION:
- Perform this step when the engine is cold.
- Never spill engine coolant on drive belt.
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.Remove drive belt. Removal and Installation.
12.Separate engine harnesses by removing their brackets from front timing chain case.
13.Remove intake manifold collector. Exploded View.
14.Remove fuel sub tube mounting bolt. Exploded View.
15.Remove oil level gauge and oil level gauge guide.
16.Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to
Exploded View.
17.Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Without 4WAS and Models Except Sport Models or With 4WAS and Sport Models.
18.Remove power steering oil pump bracket.
19.Remove idler pulley, drive belt auto-tensioner and bracket. Exploded View.
20.Remove alternator and alternator bracket. Exploded View (2WD models) or
Exploded View (AWD models).
21.Remove water pipe. Exploded View.





22.Remove camshaft position sensor (PHASE).






CAUTION:
- Handle carefully to avoid dropping and shocks.
- Never disassemble.
- Never allow metal powder to adhere to magnetic part at sensor tip.
- Never place sensors in a location where they are exposed to magnetism.
23.Remove intake valve timing control covers and gasket as follows:
a.Disconnect intake valve timing control solenoid valve harness connector.





b.Loosen mounting bolts in reverse order as shown in the figure.






CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
c.Shaft is engaged with camshaft sprocket (INT) center hole on inside. Pull straight out so that it does not tilt until the joint is disengaged.
24.Remove intake valve timing control solenoid valve, if necessary.

CAUTION:
Intake valve timing control solenoid valve is nonreusable. Never remove it unless required.
25.Remove rocker covers (bank 1 and bank 2). Exploded View.
26.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.










b.Check that exhaust cam noses on No.1 cylinder (engine front side of bank 1) is located as shown in the figure.





- If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
27.Remove crankshaft pulley as follows:





a.Remove rear cover plate and set the ring gear stopper [SST:
KV-10118600 (J-48641)] (A) as shown in the figure.










b.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 because it is 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, because this damages internal damper.
28.Remove oil pan (lower). Exploded View (2WD models) or {LINK_TO_MANY:0000000007468840}{LINK_TO_MANY:0000000007468841}, "Exploded
View (AWD)" (AWD models).





29.Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order as shown in the figure.





30.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: KV-10111100 (J-37228)] to cut liquid gasket for removal.

CAUTION:
- Never use a screwdriver or a similar item.
- After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.





31.Remove front oil seal from front timing chain case using a suitable tool.
- Use a screwdriver for removal.

CAUTION:
Be careful not to damage front timing chain case.





32.Remove O-ring (1) from rear timing chain case.










33.Remove timing chain tensioner (primary) (1) as follows:
a.Remove lower mounting bolt (A).
b.Loosen upper mounting bolt (B) slowly, and then turn timing chain tensioner (primary) on the upper mounting bolt so that plunger (C) is fully expanded.
NOTE:
Even if plunger is fully expanded, it does not drop from the body of timing chain tensioner (primary).
c.Remove upper mounting bolt, and then remove timing chain tensioner (primary).





34.Remove internal chain guide (1), slack guide (2) and tension guide (3).
35.Remove timing chain (primary) and crankshaft sprocket.

CAUTION:
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves strike the piston heads.
36.Remove timing chain (secondary) and camshaft sprockets as follows:





a.Attach suitable stopper pin (C) to the timing chain tensioners (secondary) (1), (2).





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 VVEL ladder assembly is required.)
b.Remove camshaft sprocket (EXH) mounting bolt.
- Secure the hexagonal portion of camshaft (EXH) using a wrench to loosen mounting bolt.

CAUTION:
Never loosen the mounting bolt by securing anything other than the camshaft (EXH) hexagonal portion or with tensioning the timing chain.
c.Remove camshaft sprocket (INT) mounting bolt.





- Secure the hexagonal portion (located in between journal No.
1 and journal No. 2) of drive shaft (A) using a wrench to loosen mounting bolt.






CAUTION:
- Never loosen the mounting bolt by securing anything other than the drive shaft hexagonal portion or with tensioning the timing chain.
- When holding the hexagonal part of drive shaft on the intake side with a wrench, be careful not to allow the wrench to cause interference with other parts.





- Never disassemble camshaft sprocket (INT). [Never loosen bolts (A) as shown in the figure.]
d.Remove timing chain (secondary) together with camshaft sprockets.





37.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:
Be careful not to allow gasket fragments to enter oil pan.





38.Remove old liquid gasket from bolt hole and thread.






INSTALLATION


CAUTION:
Do not reuse O-rings.
NOTE:
The figure below shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket with the components installed.















1.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 that camshaft is placed in the same direction as that of the figure.
Camshaft dowel pin


: At cylinder head upper face side in each bank.
Crankshaft key
: At cylinder head side of bank 1.
2.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.
NOTE:
Figure shows bank 1 (rear view).





- Align the matching marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets (punched), and install them.
NOTE:
- Matching marks for camshaft sprockets (INT) are on the back side of camshaft sprockets (secondary).
- There are two types of matching marks, the circle and oval types. They should be used for the bank 1 and bank 2, respectively.
Bank 1: Use circle type