Timing Chain: Service and Repair
Part 1:
Part 2:
Removal and Installation
CAUTION: Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove engine assembly from vehicle. Refer to "Removal and Installation"
2. Remove the following components and related parts:
^ Drive belt auto tensioner and idler pulley. Refer to "Drive Belt Auto Tensioner and Idler Pulley".
^ Thermostat housing and hose.
^ Oil pan and oil strainer.
^ Ignition coil (When camshaft sprocket is removed).
^ Rocker cover (When camshaft sprocket is removed).
3. If necessary, remove intake valve timing control position sensor (right and left) and camshaft position sensor (PHASE) from intake valve timing control cover and front cover.
CAUTION:
^ Handle components and parts carefully to avoid dropping and shocks.
^ Do not disassemble.
4. If necessary, remove intake valve timing control solenoid valve from intake valve timing control cover.
CAUTION:
^ Handle components and parts carefully to avoid dropping and shocks.
^ Do not disassemble.
5. Remove intake valve timing control cover as follows:
a. Loosen and remove fixing bolts in the reverse order of that shown in figure.
b. Use seal cutter or the equivalent to cut liquid gasket for removal.
CAUTION:
^ Exercise care not to damage mating surfaces.
^ Pull out cover keeping levelness without an angle, as inner part of cover is engaged with the center of intake cam sprocket.
6. Obtain compression TDC of No. 1 cylinder as follows:
a. Turn crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with timing indicator on front cover.
b. At this time, check that the mating mark on camshaft sprocket is in the position as shown in the figure.
^ If the mating mark does not come in the position shown, turn crankshaft pulley once more to bring the mark in the position.
7. Remove crankshaft pulley as follows:
a. Lock crankshaft with a hammer handle or similar tool to loosen fixing bolts.
b. Pull crankshaft pulley with both hands to remove it.
CAUTION:
^ Do not remove fixing bolts. Keep loosened fixing bolts in place to protect removed crankshaft pulley from dropping.
^ Do not remove balance weight (inner hexagon bolt) at the front of crankshaft pulley.
8. Remove front cover as follows:
a. Loosen and remove fixing bolts in the reverse order of that shown in figure.
b. Use seal cutter or the equivalent to cut liquid gasket for removal.
CAUTION: Exercise care not to damage mating surfaces.
9. If replacement of front oil seal is necessary, lift the seal with a screwdriver for removal.
10. Remove oil pump drive spacer.
^ Install bolts into two bolt holes [M6 x pitch 1.0 mm (0.04 inch)] on front surface. Using a small puller, pull spacer off from crankshaft.
NOTE: The center-to-center dimension between the two bolt holes is 33 mm (1.30 inch).
11. Remove oil pump. Refer to "OIL PUMP".
12. Remove chain tensioner on left bank.
NOTE: To remove timing chain and associated parts, start with those on left bank. The procedure for removing parts on right bank is omitted because it is the same as that for left bank.
a. Press tab in the direction of arrow (or turn lever in the direction of arrow) to unlock the locking with the groove that stops tensioner plunger from returning.
^ Lightly press tensioner plunger to release the tension of spring for this operation.
b. Push in tensioner plunger to align the hole on lever and that on pump main body
^ Pushing in tensioner too far does not allow the holes to align. Therefore, push in plunger to the degree at which the start of stopper groove and tab engages.
c. Insert a stopper pin [hard wire with approximately 0.5 mm (0.020 inch) diameter or a similar tool] to fix plunger. With plunger fixed, remove chain tensioner.
13. Remove chain tensioner guide and slack guide.
14. Remove timing chain and crankshaft sprocket.
15. With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket.
CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain is disconnected.
16. Using the same procedure as for left bank, remove timing chain and associated parts on right side.
INSPECTION AFTER REMOVAL
Check for cracks and any excessive wear at link plates. Replace chain if necessary.
INSTALLATION
NOTE:
^ The above figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.
^ Parts with an identification mark (R or L) should be installed on the corresponding bank according to the mark.
Parts with an identification mark:
^ Intake camshaft sprocket
^ Dowel pin groove of exhaust camshaft sprocket (camshaft sprocket is same part both banks)
^ Chain tension guide
^ Chain slack guide
^ Because of parallel manufacture, there are two types of mark (link colors) for timing chain.
^ To install timing chain and associated parts, start with those on right bank. The procedure for installing parts on left bank is omitted because it is the same as that for installation on right bank.
1. Check that the crankshaft key and dowel pin of each camshaft are facing in the direction indicated.
2. Install camshaft sprockets.
^ Install onto correct side by checking with identification mark on surface
^ Install exhaust-side camshaft sprocket by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.)
^ Lock the hexagonal part of camshaft in the same way as for removal, and tighten fixing bolts.
3. Install crankshaft sprockets for both banks.
^ Install each crankshaft sprocket so that its flange side (the larger diameter side without teeth) faces in the direction shown in figure.
NOTE: The same parts are used but facing directions are different.
4. Install timing chains and associated parts.
^ Align the mating mark on each sprocket and the timing chain for installation.
NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.
CAUTION: For the above reason, after the mating marks are aligned, keep them aligned by holding them with a hand.
^ Install slack guides and tension guides onto correct side by checking with identification mark on surface.
^ Install chain tensioner with plunger fixed as described in its removal.
CAUTION:
^ Before and after the installation of chain tensioner, make sure that the mating mark on timing chain is not out of alignment.
^ After installing chain tensioner, remove the stopper pin to release tensioner. Check that tensioner is released.
^ To avoid chain-link skipping of timing chain, never move crankshaft or camshafts until front cover is installed.
5. In the same way as for right bank, install timing chain and associated parts on left side.
6. Install oil pump.
7. Install oil pump drive spacer as follows:
a. Insert oil pump drive spacer according to the directions of crankshaft key and the two flat surfaces of oil pump inner rotor.
^ If the positional relationship does not allow the insertion, rotate oil pump inner rotor with a finger to allow the spacer.
b. After confirming that the position of each part is in correct condition to allow for the spacer, force fit the spacer by lightly tapping with a plastic hammer until it contacts and does not go further.
8. Install front oil seal onto front cover.
^ Using oil seal drift or drift with 54 mm (2.13 inch) diameter, force fit the seal until it levels with the front end surface of front cover.
^ Install new oil seal in the direction shown in the figure.
CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.
9. Install chain tensioner cover onto front cover.
^ Apply liquid gasket as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
10. Install front cover as follows:
a. Install new O-rings onto RH and LH cylinder heads and cylinder block.
b. Apply liquid gasket as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
c. Check again that the timing mating mark on timing chain and that on each sprocket are aligned. Then, install front cover.
CAUTION: Be careful to avoid interference with the front end of oil pump drive spacer. Such interference may damage front oil seal.
d. Tighten fixing bolts in the order shown in figure.
e. After tightening, re-tighten to the specified torque.
CAUTION: Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan.
11. Install intake valve timing control cover as follows:
a. At the back of intake valve timing control cover, install new seal rings (three for each) to the area to be inserted into intake camshaft sprocket.
CAUTION: Do not spread seal ring excessively to avoid breaks and deformation.
b. On the side of front cover, install new O-ring (one for each bank).
c. Apply liquid gasket as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
d. Tighten fixing bolts in the order shown in figure.
12. Install intake valve timing control position sensor, intake valve timing control solenoid valve and camshaft position sensor (PHASE) to intake valve timing control cover and front cover.
^ Be sure to tighten bolts with flanges completely seated.
13. Install crankshaft pulley.
^ Install according to the dowel pin of oil pump drive spacer.
^ Lightly tapping its center with plastic hammer, insert pulley.
CAUTION: Do not tap pulley on the side surface where belt is installed (outer circumference).
14. Tighten fixing bolts of crankshaft pulley
^ Lock crankshaft with a hammer handle or similar tool to tighten fixing bolts.
^ Perform the following steps for angular tightening:
a. Apply engine oil onto threaded parts of bolts and seating areas.
b. Tighten bolt 88.2 to 98.0 Nm (9.0 to 9.9 kg-m, 65 to 72 ft. lbs.).
c. Select one most visible notch of the four on bolt flange. Corresponding to the selected notch, put a mating mark (such as paint) on crankshaft pulley
d. Tighten further by 90° to 96° [target: 90°].
^ Check the tightening angle by referencing to the notches. The angle between two notches is 90°.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from FRONT) to check for interference among parts.
16. For the following operations, perform steps in the reverse order of removal.