Timing Chain: Service and Repair

REMOVAL





NOTICE: Under the condition with the timing chain cover removed, in case of rotating the camshafts, make the position of the crankshaft rotated clockwise by about 45° from TDC/compression of No. 1 cylinder.

1. REMOVE ENGINE
2. REMOVE IGNITION COILS





3. REMOVE CYLINDER HEAD COVER
a. Remove the bolt and disconnect the engine wire harness clamp.
b. Remove the 2 bolts and disconnect the engine wire harness in the rear side.
c. Disconnect the PCV hose from the PCV valve.
d. Remove the 8 bolts, 2 nuts, cylinder head cover and gasket.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION





a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.





b. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the marks.
5. TMC made:
REMOVE CRANKSHAFT PULLEY





a. Using SST, loosen the pulley bolt.
SST 09213-14010, 09330-00021





b. Remove the crankshaft pulley bolt and crankshaft pulley.

HINT: If necessary, remove the pulley with SST.

SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021), 09950-40011 (09957-04010)
6. TMMK made:
REMOVE CRANKSHAFT PULLEY





a. Hold the pulley by SST, loosen and remove the pulley bolt.
SST 09960-10010





b. Remove the pulley.
If the pulley is not removed, use SST as shown in the illustration.
SST 09950-40010 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010, 91111-51014)





7. REMOVE CHAIN TENSIONER
a. Remove the bolt and intake manifold stay.
b. Remove the 2 nuts, chain tensioner and gasket.





8. REMOVE DRIVE BELT TENSIONER
Remove the bolt, nut and drive belt tensioner.
9. REMOVE CRANKSHAFT POSITION SENSOR





10. REMOVE OIL PAN
a. Remove the 12 bolts and 2 nuts.
b. Inserting the blade of SST between the crank case and oil pan, cut off the applied sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.





11. REMOVE TIMING CHAIN COVER
a. Remove the bolt and wire clamps.
b. Remove the 14 bolts and 2 nuts.
c. Using a screwdriver, pry between the timing chain cover and cylinder head or cylinder block.
d. Remove the timing chain cover.

NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.

12. REMOVE CRANK ANGLE SENSOR PLATE





13. REMOVE CHAIN TENSIONER SLIPPER
Remove the bolt and chain tensioner slipper.
14. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and chain vibration damper.





15. REMOVE TIMING CHAIN GUIDE
Remove the bolt and timing chain guide.
16. REMOVE TIMING CHAIN
17. REMOVE CRANKSHAFT TIMING SPROCKET





18. REMOVE CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET
a. Hold the hexagonal head wrench portion of the camshaft with a wrench, and loosen the sprocket bolts.

NOTICE: Be careful not to damage the cylinder head and valve lifter by a wrench.

b. Remove the bolt and exhaust camshaft timing sprocket.
c. Remove the bolt and VVT timing sprocket.

NOTICE: Do not disassemble the VVT timing sprocket.

INSPECTION
1. INSPECT TIMING CHAIN AND TIMING SPROCKETS





a. Using vernier calipers, measure the length of 16 links with the chain dully stretched.
Maximum chain elongation: 122.6 mm (4.827 inch)
If the elongation is greater than the maximum, replace the chain.

HINT: Make the same measurements, pulling at 3 or more points selected at random.





b. Wrap the chain around the timing sprocket.
c. Using a vernier calipers, measure the timing sprocket diameter with the chain.

NOTICE: Vernier calipers must contact the chain rollers for measurement.





Minimum sprocket diameter (w/ Chain):

If the diameter is less than the minimum, replace the chain and sprockets.





2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER
Measure the chain tensioner slipper and vibration damper wears.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the slipper and/or damper.





3. INSPECT CHAIN TENSIONER
a. Check that the plunger moves smoothly when raising the ratchet pawl with your finger.
b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
4. INSPECT DRIVE BELT TENSIONER
Check the oil leakage and crack.
If necessary, replace the drive belt tensioner.

REPLACEMENT
REPLACE CRANKSHAFT FRONT OIL SEAL

HINT: There are 2 methods ((a) and (b)) to replace the oil seal.

a. If the timing chain cover is removed from the cylinder head and block.





1) Using a screwdriver and a hammer, tap out the oil seal.





2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09309-37010
3) Apply MP grease to the oil seal lip.
b. If the timing chain cover is installed to the cylinder head and block.





1) Using SST, remove the oil seal.
SST 09308-10010, 09950-60010 (09951-00200)





2) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09309-37010

INSTALLATION
1. INSTALL CAMSHAFT TIMING SPROCKET AND VVT TIMING SPROCKET
a. Install the camshaft timing sprocket.





1) Face the timing mark of the sprocket outward.
2) Align the camshaft knock pin with the knock pin groove on the sprocket side with the timing mark, and slide on the camshaft timing sprocket and VVT timing sprocket.
3) Temporarily install the camshaft timing sprocket set bolt.





4) Hold the hexagon wrench head portion of the exhaust camshaft with a wrench, and tighten the bolt.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





b. Install the VVT timing sprocket.
1) Holding the VVT timing sprocket in the position where the VVT timing sprocket pin groove is slightly to right of the camshaft pin looking from the front side, install the VVT timing sprocket to the camshaft, lightly pressing and turning it counter clockwise. Check that there is virtually no clearance between the VVT timing sprocket and camshaft flange.

NOTICE: Be careful not to turn the VVT timing sprocket clockwise when installing it.

2) Temporarily install the VVT timing sprocket bolt.
3) Hold the hexagon wrench head portion of the intake camshaft with a wrench.
4) Take care to install the VVT timing sprocket with the bolt
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)
5) Check that the valve timing controller turns clockwise and that it is locked securely when the lock pin in hole is at the locking point.
2. SET NO. 1 CYLINDER TO TDC/COMPRESSI0N





a. Turn the hexagonal wrench head portion of the camshafts, and align the timing marks of the camshaft timing sprocket and VVT timing sprocket with the timing marks of No 1 and No. 2 bearing caps as shown in the illustration.





b. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.





3. INSTALL CHAIN VIBRATION DAMPER
Install the damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
4. INSTALL CRANKSHAFT TIMING SPROCKET
Align the sprocket set key with the key groove of the sprocket, slide on the sprocket.
5. INSTALL TIMING CHAIN





a. Install the timing chain on the crankshaft timing sprocket with the blue or orange mark link aligned with the timing mark on the crankshaft timing sprocket.





b. Install the timing chain on the camshaft timing sprocket and VVT timing sprocket with the gold or yellow mark links aligned with the timing marks on the camshaft timing sprocket and VVT timing sprocket.





6. INSTALL TIMING CHAIN GUIDE
Install the timing chain guide with the bolt.
Torque: 9 Nm (90 kgf-cm, 80 inch lbs.)





7. INSTALL CHAIN TENSIONER SLIPPER
a. Install the slipper with the bolt.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
b. Check that the slipper is hold on the cylinder block stopper.





8. INSTALL CRANK ANGLE SENSOR PLATE
Install the plate with the "F" mark facing forward.
9. INSTALL TIMING CHAIN COVER





a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover and cylinder head/block/crank case.
- Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all the components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the timing chain cover as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.

HINT: Avoid applying an excessive amount to the surface.
- Parts must be assembled within 3 minutes after the application. Otherwise the material must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.





c. Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 2 mm (0.08 inch) opening.

HINT: Avoid applying an excessive amount to the surface.
- Parts must be assembled within 3 minutes after the application. Otherwise the material must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.





d. Install the timing chain cover with the 14 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque:
9 Nm (90 kgf-cm, 80 inch lbs.) for bolt A
21 Nm (220 kgf-cm, 15 ft. lbs.) for bolt B
43 Nm (440 kgf-cm, 32 ft. lbs.) for bolt C
43 Nm (440 kgf-cm, 32 ft. lbs.) for bolt D
9 Nm (90 kgf-cm, 80 ft. lbs.) for nuts





HINT: Each bolt length in indicated in the illustration.

NOTICE:
- Pay attention not to cover the chain and slipper over the chain cover seal line.
- After installing the chain cover, be sure to install the mounting bracket and water pump within 15 minutes.

e. Install the 2 wire clamps with the 2 bolts.





10. INSTALL DRIVE BELT TENSIONER
Install the drive belt tensioner with the bolt and nut.
Torque: 59.5 Nm (610 kgf-cm, 44 ft. lbs.)

NOTICE: As the drive belt tensioner should be torqued together with the timing chain cover, so be sure. Install it with in 15 minutes after the timing chain cover is Installed.

11. INSTALL CRANKSHAFT POSITION SENSOR
12. INSTALL OIL PAN





a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the main bearing cap and oil pan.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all the components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.

NOTICE: Do not use a solvent which will affect the painted surfaces.

b. Apply seal packing to the oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 4.0 mm (0.157 inch) opening.

HINT: Avoid applying an excessive amount to the surface.
- Parts must be assembled within 3 minutes after the application. Otherwise the material must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.





c. Install the oil pan with the 12 bolts and 2 nuts.
Torque: 8.8 Nm (90 kgf-cm, 78 inch lbs.)
13. TMC made:
INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.





b. Using SST, install the pulley bolt.
SST 09213-54015, 09330-00021
Torque: 170 Nm (1,735 kgf-cm, 125 ft. lbs.)
14. TMMK made:
INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.





b. Using SST, install the pulley bolt.
SST 09960-10010
Torque: 170 Nm (1,735 kgf-cm, 125 ft. lbs.)
15. INSTALL CHAIN TENSIONER





a. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger will not spring out.





b. Place a new gasket on the timing chain cover with portion A facing as shown in the illustration.





c. Push the chain tensioner into the timing chain cover, and install the 2 nuts.
Torque: 9 Nm (90 kgf-cm, 80 inch lbs.)
d. Install the intake manifold stay with the bolts.
16. SET CHAIN TENSION





a. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.





b. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.





c. Turn the crankshaft pulley, and align its groove with timing mark "0" on the timing chain cover.

NOTICE: Always turn the crankshaft clockwise.





d. Check that the timing marks of the camshaft timing sprocket and VVT timing sprocket are aligned with the timing marks of the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the marks.
17. INSTALL CYLINDER HEAD COVER
a. Remove any old packing (FIPG) material.





b. Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the gasket to the cylinder head cover.
If the gasket has damage, replace a new one.

HINT: Parts must be assembled within 3 minutes after the application. Otherwise the material must be removed and reapplied.





d. Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque: 11 Nm (110 kgf-cm, 8 ft. lbs.)
e. Connect the PCV hose to the PCV valve.
f. Install the engine wire harness with the bolt.
g. Install the engine wire harness rear side with the 2 bolts.
18. INSTALL IGNITION COILS
19. INSTALL ENGINE