Timing Chain: Service and Repair
Timing chain removal and installation
CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
When installing rocker arms, camshafts, chain tensioner, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.
Do not spill engine coolant on drive belts.
Removal
1. Release fuel pressure.
2. Remove engine under covers.
3. Remove front RH wheel and engine side cover.
4. Drain coolant by removing cylinder block drain plug and radiator drain cock.
5. Remove radiator.
6. Remove air duct to intake manifold.
7. Remove drive belts and water pump pulley.
8. Remove alternator and power steering pump.
9. Disconnect the following parts:
Vacuum hoses
Fuel hoses
Wires
Harness
Connectors
10. Remove all spark plugs.
11. Remove rocker cover and oil separator.
12. Remove intake manifold supports.
13. Remove oil filter bracket and power steering oil pump bracket.
14. Set No.1 piston at TDC on the compression stroke by rotating crankshaft.
Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.
15. Remove chain tensioner.
16. Remove distributor.
Do not turn rotor with distributor removed.
17. Remove timing chain guide.
18. Remove camshaft sprockets.
19. Remove camshafts, camshaft brackets, oil tubes and baffle plate.
20. Remove starter motor.
21. Remove the following water hoses.
Water hose for cylinder block.
Water hoses from heater.
22. Remove knock sensor harness connector.
23. Remove cylinder head outside bolts.
24. Remove cylinder head bolts.
Bolts should be loosened in two or three steps.
25. Remove cylinder head completely with intake and exhaust manifolds.
26. Remove oil pans.
27. Remove oil strainer and baffle plate.
28. Remove crankshaft pulley.
29. Set a suitable transmission jack under main bearing beam.
30. Remove front engine mounting.
31. Remove front cover.
32. Remove timing chain guides and timing chain.
Inspection
Check for cracks and excessive wear at roller links. Replace chain If necessary.
Installation
1. Install crankshaft sprocket on crankshaft.
2. Position crankshaft so that No.1 piston is set at TDC (Key way at 12 o'clock, and mating mark at 4 o'clock approximately). Fit timing chain to crankshaft sprocket, with its mating mark in line with crankshaft sprocket mating mark.
Mating mark color on timing chain.
01 :Gold
02, 03 : Silver
3. Install timing chain and timing chain guides.
4. Before installing front cover, remove all traces of liquid gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of cylinder block.
5. Apply a continuous bead of liquid gasket to mating surface of front cover.
Use Genuine Liquid Gasket or equivalent.
6. Install oil pump drive spacer and front cover.
Wipe off excessive liquid gasket.
7. Install front engine mounting.
8. Install crankshaft pulley.
9. Set No.1 piston at TDC on its compression stroke.
10. Install oil strainer and baffle plate.
11. Install oil pan.
12. Before installing cylinder head gasket, apply a continuous bead of liquid gasket to mating surface of cylinder block.
13. Install cylinder head completely with intake and exhaust manifolds.
CAUTION: The cylinder head bolts can be reused providing dimension "A" is not exceeded.
Dimension "A": 158.2 mm (6.228 in)
Tightening procedure:
A Tighten all bolts to 39 Nm (4.0 kg-m, 29 ft-lb).
B Tighten all bolts to 78 Nm (8.0 kg-m, 58 ft-lb).
C Loosen all bolts completely.
D Tighten all bolts to 34 to 44 Nm (3.5 to 4.5 kg-m, 25 to 33 ft-lb).
E Method A: Turn all bolts 90 ±5° clockwise with Tool or suitable angle wrench.
Method B: If angle wrench is not available, do the following. Mark the side of all bolts with paint marks facing the front of the engine. Then turn them 90 ±5° clockwise.
F Turn all bolts 90 ±5° clockwise.
G Ensure that paint mark on each bolt faces the rear of the engine. (Method B only)
Do not turn any bolt 180 to 190 degrees clockwise all at once.
14. Install cylinder head outside bolts.
15. Install the following water hoses.
Water hose for cylinder block.
Water hoses for heater.
16. Install knock sensor harness connector.
17. Install starter motor.
18. Before installing LH camshaft end bracket, remove all traces of liquid gasket from mating surface.
Also remove traces of liquid gasket from mating surface of cylinder head.
19. Apply a continuous bead of liquid gasket to mating surface of LH camshaft end bracket.
Use Genuine Liquid Gasket or equivalent.
20. Install camshafts, camshaft brackets, oil tubes and baffle plate.
Position camshaft.
LH camshaft key at about 12 o'clock
RH camshaft key at about 10 o'clock
Apply engine oil to bearings and cam surfaces of camshafts before installing them.
Position camshaft brackets as shown in the illustration.
Apply engine oil to threads and seating surfaces of camshaft bracket bolts before installing them.
Tightening procedure
STEP 1:
RH camshaft: Tighten bolts 09 - 10 in that order then tighten bolts 1 - 8 in that order. 2 Nm (0.2 kg-m, 17 in-lb)
LH camshaft: Tighten bolts 11 - 12 In that order then tighten bolts 1 - 10 in that order. 2 Nm (0.2 kg-m, 17 in-lb)
STEP 2:
Tighten bolts in the specified order: 6 Nm (0.6 kg-m, 52 in-lb)
STEP 3:
Tighten bolts in the specified order.
9.8 - 11.8 Nm (1.0 - 1.2 kg-m, 87 - 104 in-lb)
Bolt type A, B, D, E, F
18-25 Nm (1.8 - 2.6 kg-rn, 13 - 19 ft-lb)
Bolt type C
21. Install camshaft sprockets.
Line up mating marks on timing chain with mating marks on camshaft sprockets.
Lock camshafts as shown in figure and tighten to specified torque. 131 - 151 Nm (14.0 - 16.0 kg-m, 101 - 116 ft-lb)
22. Install timing chain guide.
23. Install distributor.
Make sure that position of camshaft is as shown in figure.
Make sure that No.1 piston is set at TDC and that distributor rotor is set at No.1 cylinder spark position.
24. Install chain tensioner.
Make sure the camshaft sprockets are tightened completely. Press cam stopper down and "press-In" sleeve until hook can be engaged on pin. When tensioner Is bolted In position the hook will release automatically. Ensure arrow "A" faces the front of the engine.
25. Install oil filter bracket and power steering oil pump bracket.
26. Install intake manifold supports.
27. Remove liquid gasket from mating surface of rocker cover gasket to cylinder head before installing rocker cover.
28. Apply a continuous bead of liquid gasket to mating surface of rocker cover gasket and cylinder head.
Use Genuine Liquid Gasket or equivalent.
29. Install rocker cover and oil separator.
Rocker cover tightening procedure:
(1) Tighten nuts 1- 10 - 11 - 13 - 8 in that order to 4 Nm (0.4 kg-m, 35 in-lb).
(2) Tighten nuts 1 to 13 as indicated in figure to 8 to 10 Nm (0.8 to 1.0 kg-m, 69 - 87 in-lb).
30. Install the following parts:
Spark plugs and leads
Power steering pump
Alternator
Water pump pulley and drive belts.
Radiator: Refit hoses and refill with coolant.
Front RH wheel
Engine under covers
31. Connect the following:
Vacuum hoses
Fuel hoses
Wire, Harnesses and connectors
Air duct to intake manifold