Removal And Installation

TIMING CHAIN

Removal and Installation


REMOVAL


CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
1.Drain engine oil. Draining.

CAUTION:
Perform this step when engine is cold.
2.Remove the following parts:
- Intake manifold: Exploded View.
- Rocker cover: Exploded View.
3.Set No. 1 cylinder at TDC on its compression stroke with the following procedure:





a.Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover.










b.At the same time, check that the cam noses of the No. 1 cylinder are located (black arrow) as shown in the figure.





- If not, rotate crankshaft pulley one revolution (360 degrees)
and align as shown in the figure.
4.Remove crankshaft pulley with the following procedure:





a.Fix crankshaft pulley (1) with a pulley holder (commercial service tool) (A), loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position.

CAUTION:
Never remove the crankshaft pulley bolt as they will be used as a supporting point for the pulley puller [SST:
KV-11103000 (-)].





b.Attach a pulley puller [SST: KV-11103000 (-)] (A) in the M6
thread hole on crankshaft pulley (1), and remove crankshaft pulley.
5.Remove oil pan (lower). Exploded View.
NOTE:
If crankshaft sprocket and oil pump drive component are not removed, this step is unnecessary.
6.Remove intake valve timing control solenoid valve and exhaust valve timing control valve.
7.Remove drive belt auto-tensioner. Exploded View.
8.Remove front cover with the following procedure:





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





b.Cut liquid gasket by prying the position (black arrow) shown in the figure, and then remove the front cover.

CAUTION:
- Be careful not to damage the mating surface.
- A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
9.Remove front oil seal from front cover.

CAUTION:
Be careful not to damage front cover.
- Lift up front oil seal using a screwdriver.
10.Remove valve timing control cover, if necessary.





- Loosen mounting bolts in reverse order as shown in the figure.
NOTE:
Disregard the numerical order No.1 in removal.
11.Remove timing chain tensioner with the following procedure:





a.Insert a wire (A) (e.g. clip) into the top groove with the timing chain tensioner plunger pressed.
NOTE:
Timing chain tensioner plunger is securely fixed by inserting a wire (e.g. clip).
b.Remove timing chain tensioner (1).





12.Remove slack guide (2), tension guide (3) and timing chain (1).

CAUTION:
Never rotate each crankshaft and camshaft individually while timing chain is removed. It causes interference between valve and piston.
NOTE:
If timing chain is difficult to remove, remove camshaft sprocket (EXH) first to remove timing chain.
13.Remove crankshaft sprocket and oil pump drive component with the following procedure:





a.Push oil pump drive chain tensioner (1) in the direction show in the figure.
b.Insert a stopper pin (A) into the body hole (B).
c.Remove oil pump chain tensioner.
- When the holes on lever and tensioner body cannot be alined, align these holes by slightly moving the oil pump chain tensioner slack guide.





d.Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A), and then loosen the oil pump sprocket bolt and remove it.






CAUTION:
- Secure the oil pump shaft with the WAF part.
- Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
14.Remove tension guide (front cover side) from front cover, if necessary.

INSTALLATION


CAUTION:
Do not reuse O-rings.
NOTE:





The figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.





1.Check that crankshaft key points straight up.
2.If the tension guide (front cover side) is removed, install it to the front cover.

CAUTION:
Check the joint condition by sound or feeling.





3.Install crankshaft sprocket (2), oil pump sprocket (3), and oil pump drive chain (1).





- Install it by aligning matching marks on each sprockets and oil pump drive chain.
- If these matching marks are not aligned, rotate the oil pump shaft slightly to correct the position.

CAUTION:
Check matching mark position of each sprockets after installing the oil pump drive chain.





4.Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A), and then tighten the oil pump shaft sprocket bolt.






CAUTION:
- Secure the oil pump shaft with the WAF part.
- Never loosen the oil pump shaft sprocket bolt by tightening the oil pump drive chain.





5.Install oil pump chain tensioner (1).
- Fix the face oil pump tensioner at the most compressed position using a stopper pin (A), and then install it.
- Securely pull out (black arrow) the stopper pin after installing the oil pump chain tensioner.
- Check matching mark position of oil pump drive chain and each sprockets again.





6.Align the matching marks of each sprockets with the matching marks of timing chain.





- If these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion to correct the position.

CAUTION:
Check matching mark position of each sprocket and timing chain again after installing the timing chain.





7.Install the slack guide (2) and the tension guide (3).





8.Install timing chain tensioner.
- Fix the plunger at the most compressed position using a stopper pin, and then install it.
- Securely pull out the stopper pin after installing the timing chain tensioner.

CAUTION:
- After installing tensioner on the cam side, pull out lock pin.
- If plunger pops out after pulling out lock pin without installing the tensioner to the engine, never use the tensioner. (If used, the plunger does not slide smoothly.)
- To reuse tensioner on the cam side:
After installation, pick up and move ratchet clip toward the tip of the plunger and position the tensioner parallel to the groove of the plunger.
9.Check matching mark position of timing chain and each sprockets again.
10.Install front oil seal. Service and Repair.
11.Install front cover with the following procedure:
a.Install valve timing control cover, if removed.





- Apply a continuous bead of liquid gasket (E) with a tube presser (commercial service tool) to valve timing control cover as shown in the figure.





NOTE:
The start and end of gasket application must overlap 5mm or more one another.





- Tighten mounting bolts in numerical order as shown in the figure.
NOTE:
Tighten bolt the No.1 in two step. The numerical order No.6
shows the second step.
b.Install new O-ring to cylinder block.

CAUTION:
Do not reuse O-rings.





c.Apply a continuous bead of liquid gasket (D) with a tube presser (commercial service tool) to front cover as shown in the figure.





Use Genuine RTV Silicon Sealant or equivalent. Recommended Chemical Products And Sealants
.
d.Check that matching marks of timing chain and each sprockets are still aligned. Then install front cover.

CAUTION:
- Check O-ring on cylinder block is correctly installed.
- Be careful not to damage front oil seal by interference with front end of crankshaft.





e.Install front cover, and tighten mounting bolts in numerical order as shown in the figure.
- Refer to the following for the installation position of bolts.






CAUTION:
Attaching should be done within 5 minutes after liquid gasket application.
f.After all bolts are tightened, retighten them to specified torque in numerical order as shown in the figure.

CAUTION:
Be sure to wipe off any excessive liquid gasket leaking.
12.Install crankshaft pulley with the following procedure:
a.When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).

CAUTION:
Never damage front oil seal lip section.





b.Secure crankshaft pulley (1) with a pulley holder (commercial service tool) (A).
c.Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
d.Tighten crankshaft pulley bolt :











e.Put a paint mark (B) on crankshaft pulley (2), matching with any one of six easy to recognize angle marks (A) on crankshaft pulley bolt (1) flange.
f.Turn another 60 degrees clockwise (angle tightening).
- Check the tightening angle with movement of one angle mark.
g.Check that crankshaft rotates clockwise smoothly.
13.Install remaining parts in the reverse order of removal.