Installation

TIMING CHAIN - Continued

Removal and Installation

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
Bank 2: Use oval type





- Shape (orientation of signal plate) of camshaft sprocket (INT)
varies depending on the bank position. See the right figure to install.





- Align dowel pin camshafts with the pin groove on sprockets, and install them.
- In case that positions of each matching mark and each dowel pin do not fit with matching parts, make fine adjustment to the position holding the hexagonal portion on camshaft (EXH) or drive shaft with wrench or equivalent tool.
- Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is sufficient to prevent the dislocation of dowel pins.





- It may be difficult to visually check the dislocation of matching marks during and after installation. To make the matching easier, make a matching mark on the top of sprocket teeth and its extended line in advance with paint.





c.Tighten camshaft sprocket (EXH) mounting bolt.
- Secure camshaft (EXH) using a wrench at the hexagonal portion to tighten mounting bolt.
d.After confirming the matching marks are aligned, tighten 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 tighten mounting bolt.






CAUTION:
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.





e.Pull stopper pins (C) out from timing chain tensioners (secondary) (1), (2).





3.Install timing chain (primary) as follows:





a.Install crankshaft sprocket (1).





- Check that the matching marks on crankshaft sprocket face the front of the engine.
b.Install timing chain (primary).





- Install timing chain (primary) so that 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 drive shaft using wrench on the hexagonal portion to align it with the matching marks.





4.Install internal chain guide (1), slack guide (2), and tension guide (3).

CAUTION:





Never overtighten slack guide mounting bolt (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolt are tightened to the specification.





5.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 is 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.
6.Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.





7.Install new O-rings (1) on rear timing chain case.






CAUTION:
Do not reuse O-rings.





8.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 that the garter spring is in position and seal lip is not inverted.
9.Install front timing chain case as follows:
- Check that 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" 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" Recommended Chemical Products and Sealants
.





c.Assemble front timing chain case.






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.
d.Install front timing chain case fitting its dowel pin hole together with 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.

M10 bolts: 1, 2, 3, 4, 5, 6, 7
: 55.0 Nm (5.6 kg-m, 41 ft-lb)
M6 bolts: Except the above
: 12.7 Nm (1.3 kg-m, 9 ft-lb)

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: Refer to "Exploded View" Exploded View.
10.Install intake valve timing control covers as follows:





a.Install new seal rings (1) in shaft grooves.






CAUTION:
When replacing seal ring, replace all rings with new ones.
NOTE:
The figure shows an example of bank 2.
b.Install intake 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 intake side camshaft sprocket, and then insert them.
- Be careful not to 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 dowel pin holes (C) to install intake valve timing control covers.





d.Tighten mounting bolts in numerical order as shown in the figure.
- After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
11.Install oil pan (lower). Refer to "Exploded View" Exploded View.
12.Install rocker covers (bank 1 and bank 2). Refer to "Exploded View" Exploded View.
13.Install crankshaft pulley as follows:
a.Fix crankshaft using the 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.

: 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.
14.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)





b.Tighten mounting bolts to specified torque in numerical order as shown in the figure.
15.For the following operations, perform steps in the reverse order of removal.