Timing Chain: Service and Repair
Removal and InstallationEM-48 Exploded View (Part 1):
EM-48 Exploded View (Part 2):
REMOVAL
1. Release the fuel pressure. Refer to EC-601, "Inspection".
Service and Repair
2. Disconnect the battery cable from the negative terminal.
3. Remove engine cover with power tool.
4. Remove radiator reservoir tank.
5. Remove air duct and air cleaner case assembly (RH and LH).
6. Remove engine undercover with power tool.
7. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when the engine is cold.
^ Never spill engine coolant on drive belt.
8. Remove radiator hose (upper and lower).
9. Drain engine oil.
CAUTION:
Perform this step when the engine is cold.
10. Remove radiator cooling fan assembly.
11. Remove drive belt.
12. Separate engine harnesses by removing their brackets from front timing chain case.
13. Remove oil cooler tube.
14. Remove intake manifold collector.
15. Remove fuel sub tube mounting bolt.
16. Remove oil level gauge and oil level gauge guide.
17. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside.
18. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
19. Remove power steering oil pump bracket.
20. Remove idler pulley, drive belt auto-tensioner and bracket.
21. Remove alternator and alternator bracket.
22. Remove water pipe.
23. Remove camshaft position sensor (PHASE).
A: Keep free from magnetic materials
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.
24. 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.
A: Bank 1
B: Bank 2
C: Dowel pin hole
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.
25. Remove intake valve timing control solenoid valve, if necessary.
CAUTION:
Intake valve timing control solenoid valve is non reusable. Never remove it unless required.
26. Remove rocker covers (bank 1 and bank 2).
27. 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.
<---: Timing mark (grooved line without color)
b. Check that exhaust cam noses on No.1 cylinder (engine front side of bank 1) is located as shown in the figure.
1: Camshaft (EXH) (bank 1)
<---: Engine front
^ If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
28. Remove crankshaft pulley as follows:
a. Remove rear cover plate and set the ring gear stopper [SST: KV10118600 (J-48641)] (A) as shown in the figure.
1: Oil pan (upper)
2: Flywheel (M/T models) or drive plate (A/T models)
<---: Vehicle front
b. Loosen crankshaft pulley bolt and rotate bolt seating surface at 10 mm (0.39 in) from its original position.
1: Crankshaft pulley
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.
29. Remove oil pan (lower).
30. Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order as shown in the figure.
<---: Engine front
31. 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 (J37228)] 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.
32. 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.
33. Remove O-ring (1) from rear timing chain case.
A: Bank 1
B: Bank 2
34. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (1).
b. Loosen upper mounting bolt (2) slowly, and then turn timing chain tensioner (primary) (3) on the upper mounting bolt so that plunger (4) 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).
35. Remove internal chain guide (1), slack guide (2) and tension guide (3).
36. 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.
37. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin (C) to the timing chain tensioners (secondary) (1), (2).
A: Bank 1
B: Bank 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 EM-83, "Exploded View". Service and Repair
(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.
1: Camshaft (EXH) (bank 2)
<---: Engine front
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.
38. 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.
39. Remove old liquid gasket from bolt hole and thread.
A: Remove old liquid gasket that is stuck
B: Bolt hole
INSTALLATION
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).
A: Camshaft sprocket (INT) back face
B: Orange link
C: Dowel groove
D: Matching mark (oval)
E: Matching mark (2 oval: on front face)
F: Matching mark (circle)
G: Camshaft sprocket (EXH) back face
H: Matching mark (2 circle: on front face)
I: Timing chain (secondary)
^ 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
^ 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.
A: Matching mark (painted)
B: Matching mark (orange link)
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.
1: Camshaft (EXH) (bank 2)
<---: Engine front
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).
A: Bank 1
B: Bank 2
3. Install timing chain (primary) as follows:
a. Install crankshaft sprocket (1).
A: Matching mark (front side)
<---: Engine front
^ 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.
3: Water pump
^ 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.
1: Slack guide
3: Cylinder block
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.
A: Bank 1
B: Bank 2
8. Install new front oil seal on front timing chain case.
<---: Engine inside
<---: Engine outside
^ 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.
B: Protrusion
C: 3.4 - 4.4 mm (0.134 - 0.173 in) dia.
d: 2.6 - 3.6 mm (0.102 - 0.142 in) dia.
e: 4.0 - 5.6 mm (0.157 - 0.220 in)
b. Apply liquid gasket to top surface of oil pan (upper) as shown in the figure.
A: 4.0 - 5.0 mm (0.157 - 0.197 in) dia.
Use Genuine RTV Silicone Sealant or equivalent.
c. Assemble front timing chain case.
1: Front timing chain case
2: Oil pan (upper)
3: Cylinder block
<---: Engine front
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.
<---: Engine front
Tightening torque: Refer to EM-75, "Exploded View". Upper
10. Install intake valve timing control covers as follows:
a. Install new seal rings (1) in shaft grooves.
A: Bank 2
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.
A: Bank 1
B: Bank 2
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).
12. Install rocker covers (bank 1 and bank 2).
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.
Torque: 44.1 Nm (4.5 kg-m, 33 ft-lb)
d. Tighten the bolt 90° (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. For the following operations, perform steps in the reverse order of removal.
Inspection
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and any excessive wear at link plates and roller links of timing chain. Replace timing chain as necessary.
A: Crack
B: Wear
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluid leakage, lubricant leakage.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the required quantity, fill them to the specified level.
^ Follow the procedure below to check for fuel leakage.
^ Turn ignition switch to the "ON" position (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
^ Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise will stop after hydraulic pressure rises.
^ Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to the specified level, if necessary.
