TIMING CHAIN ASSEMBLY
id011000505600
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Caution
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• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage the rocker arm. To prevent damage to the rocker arm when holding the camshaft on the cast hexagon, use the wrench at engine rear side as shown in the figure to secure a clearance between the cam.
• When installing the oil pan, refer to the Oil Pan Installation Note and apply the silicone sealant correctly. If the silicone sealant application position is incorrect or there is any break in the application track, engine oil leakage will occur due to a poor seal.
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Note
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• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.
1. Assemble in the order indicated in the table.
Vehicles with IDEVA (single tensioner type)
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1
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Key
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2
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Oil pump drive sprocket
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3
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Oil pump chain guide
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4
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Oil pump chain
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5
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Oil pump driven sprocket
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6
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Oil pump chain tensioner
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7
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Oil pump driven sprocket installation bolt
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8
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Crankshaft sprocket
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9
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Timing chain
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10
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Timing chain guide
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11
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Timing chain tensioner arm
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12
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Timing chain tensioner
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13
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Engine front cover
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14
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Oil pan
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15
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Front oil seal
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16
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Crankshaft pulley
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17
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Crankshaft pulley lock bolt
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18
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Water pipe
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19
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Oil shower pipe
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20
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Pressure regulator valve
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21
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Oil baffle plate
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22
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Cylinder head cover
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23
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Dipstick
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Vehicles with IDEVA (dual tensioner type)
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1
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Key
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2
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Oil pump drive sprocket
|
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3
|
Oil pump chain
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4
|
Oil pump driven sprocket
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5
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Oil pump chain tensioner No.1
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6
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Oil pump chain tensioner No.2
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7
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Oil pump driven sprocket installation bolt
|
|
8
|
Crankshaft sprocket
|
|
9
|
Timing chain
|
|
10
|
Timing chain guide
|
|
11
|
Timing chain tensioner arm
|
|
12
|
Timing chain tensioner
|
|
13
|
Engine front cover
|
|
14
|
Oil pan
|
|
15
|
Front oil seal
|
|
16
|
Crankshaft pulley
|
|
17
|
Crankshaft pulley lock bolt
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|
18
|
Water pipe
|
|
19
|
Oil shower pipe
|
|
20
|
Cylinder head cover
|
|
21
|
Dipstick
|
Vehicles without IDEVA
|
1
|
Key
|
|
2
|
Oil pump drive sprocket
|
|
3
|
Oil pump chain
|
|
4
|
Oil pump driven sprocket
|
|
5
|
Oil pump chain tensioner No.1
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6
|
Oil pump chain tensioner No.2
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7
|
Oil pump driven sprocket installation bolt
|
|
8
|
Crankshaft sprocket
|
|
9
|
Timing chain
|
|
10
|
Timing chain guide
|
|
11
|
Timing chain tensioner arm
|
|
12
|
Timing chain tensioner
|
|
13
|
Engine front cover
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|
14
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Engine oil level sensor
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15
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Oil pan
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16
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Front oil seal
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17
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Crankshaft pulley
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|
18
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Crankshaft pulley lock bolt
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19
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Oil shower pipe
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20
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Cylinder head cover
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21
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Dipstick
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Oil Pump Chain Assembly Note
Single tensioner type
1. Verify that the key and knock pin are aligned to the positions shown in the figure.
2. Align the oil pump chain alignment marks with the oil pump driven sprocket alignment marks.
Type A
Type B
3. Install the oil pump chain and oil pump driven sprocket as a single unit while aligning the alignment marks on each sprocket and oil pump chain as shown in the figure.
Type A
Type B
4. Temporarily tighten the oil pump driven sprocket installation bolt.
5. Install the oil pump chain tensioner.
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Tightening torque
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8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
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Caution
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• At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.
6. Tighten the oil pump driven sprocket installation bolt using the following procedure.
- (1) Lock the oil pump driven sprocket against rotation using the SST.
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- (2) Tighten the oil pump driven sprocket installation bolt.
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Tightening torque
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123—140 N·m {13—14 kgf·m, 91—103 ft·lbf}
7. Remove the wire or paper clip installed to the oil pump chain tensioner and apply tension to the oil pump chain.
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• If a new oil pump chain tensioner is used, remove the installed stopper.
Dual tensioner type
1. Verify that the key and knock pin are aligned to the positions shown in the figure.
2. Align the oil pump chain alignment marks with the oil pump driven sprocket alignment marks.
3. Install the oil pump chain and oil pump driven sprocket as a single unit while aligning the alignment marks on each sprocket and oil pump chain as shown in the figure.
4. Temporarily tighten the oil pump driven sprocket installation bolt.
5. Install the oil pump chain tensioner No.1.
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Tightening torque
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8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
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Caution
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• At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.
6. Install the oil pump chain tensioner No.2.
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Tightening torque
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Bolt A: 20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}
Bolt B: 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
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Caution
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• At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.
7. Tighten the oil pump driven sprocket installation bolt using the following procedure.
- (1) Lock the oil pump driven sprocket against rotation using the SST.
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- (2) Tighten the oil pump driven sprocket installation bolt.
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Tightening torque
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123—140 N·m {13—14 kgf·m, 91—103 ft·lbf}
8. Remove the wire or paper clip installed to the oil pump chain tensioner and apply tension to the oil pump chain.
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• If a new oil pump chain tensioner is used, remove the installed stopper.
Timing Chain Assembly Note
1. Verify that the timing marks and the key are aligned to the position shown in the figure.
2. Align the timing chain alignment mark with the crankshaft sprocket alignment mark.
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Note
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• There are two timing chain alignment marks as shown in the figure. When assembling the timing chain and crankshaft sprocket, either timing chain alignment mark can be used.
3. Install the timing chain and crankshaft sprocket as a single unit while aligning the marks on each sprocket and the timing chain as shown in the figure.
4. Install the timing chain guide.
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Tightening torque
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20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}
5. Install the timing chain tensioner arm.
6. Install the timing chain tensioner.
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Tightening torque
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8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
7. After installing the chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing chain.
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• If a new chain tensioner is used, remove the installed stopper.
8. Verify that there is no looseness in the timing chain, and re-verify that each sprocket is in the specified location.
9. Rotate the crankshaft clockwise two turns and inspect the valve timing.
Engine Front Cover Assembly Note
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Note
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• For a new engine front cover, the positioning pins in the two locations shown in the figure project to the outside of the engine.
1. If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.
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Caution
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• If a bolt with silicone sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.
2. When reusing the engine front cover installation bolts, remove silicone sealant adhering to the bolts.
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Caution
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• If oil, dirt and silicone sealant remains on the silicone sealant application area, the silicone sealant will not seal which will cause oil leakage.
3. Completely clean and remove any oil, dirt, silicone sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.
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Caution
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• Apply the silicon sealant in a single, unbroken line.
• To prevent silicone sealant from hardening, adhere the engine front cover to the cylinder block within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.
4. Apply silicone sealant (TB1217D or equivalent) to the engine front cover as shown in the figure.
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Thickness
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A: 2—6 mm {0.1—0.2 in}
B: 4—6 mm {0.16—0.23 in}
C: 4—8 mm {0.2—0.3 in}
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Caution
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• Apply the silicone sealant so that it goes into the cylinder head gasket.
5. Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.
6. Install the engine front cover to the engine.
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Caution
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• For the number 1 and 8 bolts of the tightening order, install the bolts with new washers.
7. Tighten the engine front cover installation bolts in the order shown in the figure.
Tightening torque
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Installation position
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Tightening torque
|
|
1—19
|
20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf}
|
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20—22
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40—55 N·m {4.1—5.6 kgf·m, 30—40 ft·lbf}
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Oil Pan Assembly Note
1. Completely clean and remove any oil, dirt, silicone sealant or other foreign matter that may be adhering to the cylinder block and oil pan.
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Caution
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• Apply the silicone sealant in a single, unbroken line around the whole perimeter.
• To prevent silicone sealant from hardening, adhere the oil pan to the cylinder block within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.
2. Apply silicone sealant (TB1217D or equivalent) to the oil pan and the cylinder block.
Oil pan
Cylinder block
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Thickness
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3.0—7.0 mm {0.12—0.27 in}
3. Install the oil pan to the cylinder block.
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Caution
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• Remove any silicone sealant which oozes out into an oil pan installation bolt hole. If silicone sealant penetrates an oil pan installation bolt hole, the cylinder block could become damaged.
• There are two types of oil pan installation bolts of different lengths and shapes. Install each bolt to the specified position according to the following procedure. In addition, use new bolts because the oil pan installation bolts cannot be reused.
4. Install the oil pan using the following procedure:
- (1) Install the oil pan installation bolts as shown in the figure.
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- (2) Temporarily tighten the two bolts shown in the figure.
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- (3) Tighten the bolts in the order shown in the figure.
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Tightening torque
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8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Front Oil Seal Assembly Note
1. Apply clean engine oil to the inner surface of a new front oil seal.
2. Insert the front oil seal into the engine front cover by hand.
3. Tap the front oil seal in evenly using the SST and a hammer.
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Front oil seal press on amount
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0—0.5 mm {0—0.019 in} from edge surface of engine front cover
Crankshaft Pulley Lock Bolt Assembly Note
1. Tighten the crankshaft pulley lock bolt using the following procedure:
- (1) Hold the crankshaft using the SST.
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MTX
ATX
- (2) Tighten the crankshaft pulley lock bolt.
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Tightening procedure
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Step 1:100—120 N·m {11—12 kgf·m, 74—88 ft·lbf}
- (3) Place a paint mark on the crankshaft pulley lock bolt and crankshaft pulley as shown in the figure to tighten the bolt to the specified angle correctly.
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- (4) Tighten the crankshaft pulley lock bolt to the specified angle.
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Tightening procedure
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Step 2: 55—65°
Water Pipe Assembly Note
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Caution
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• Do not apply oil (such as engine oil, ATF) to the O-ring. Otherwise, the O-ring could swell causing a seal malfunction.
• Install the water pipe so as not to damage the O-ring. Otherwise, it could cause a seal malfunction.
1. Install the water pipe following procedure:
- (1) Apply engine coolant to the O-ring.
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- (2) Install the water pipe.
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Tightening torque
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8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Oil Shower Pipe Assembly Note
1. Install the oil shower pipe in the order shown in the figure.
Vehicles with IDEVA
Vehicles without IDEVA
Tightening torque
|
Installation position
|
Tightening torque
|
|
1
|
9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}
|
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2, 3
|
8.0—9.0 N·m {82—91 kgf·cm, 71—79 in·lbf}
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Pressure Regulator Valve Assembly Note
1. Verify that there is no damage on the gasket shown in the figure.
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• If there is any malfunction, replace the gasket.
2. Install the pressure regulator valve.
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Tightening torque
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8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
Cylinder Head Cover Assembly Note
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Caution
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• To assure the sealing performance of the cylinder head cover, be careful of the following:
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― Verify that the cylinder head cover gasket is inserted into the cylinder head cover groove and install the cylinder head cover.
― Completely clean and remove any oil, dirt, sealant or other foreign material from the seal surface.
1. Install the oil seal on the cylinder head cover.
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• Verify that the oil seal is not damaged, and replace the oil seal if it is damaged.
2. Insert a new cylinder head cover gasket into the cylinder head cover groove.
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Caution
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• To prevent silicone sealant from hardening, adhere the cylinder head cover and the cylinder head within 10 min. after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.
3. Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.
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Engine front side
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Engine rear side
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• There are two types of rear camshaft caps and the application procedures for the silicone sealant differ. Verify the shape of the rear camshaft cap beforehand and apply silicone sealant as shown in the figure.
4. Install the cylinder head cover.
5. Tighten the cylinder head cover installation bolts using the following procedure:
- (1) Temporarily tighten the two bolts shown in the figure.
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- (2) Tighten installation bolts A in the order shown in the figure.
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Tightening torque
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6.0—8.0 N·m {62—81 kgf·cm, 54—70 in·lbf}
- (3) Tighten installation bolts B in the order shown in the figure.
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Tightening torque
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4.5—7.0 N·m {46—71 kgf·cm, 40—61 in·lbf}
