Removal and Inspection

CAUTION:
- After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
- When installing camshafts, chain tensioners, 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.
- Before disconnecting fuel hose, release fuel pressure.
- Do not spill engine coolant on drive belts.

REMOVAL






1. Remove engine assembly from vehicle.
2. Remove the following parts.
- Engine mounts
- Alternator
- Air conditioner compressor
- Exhaust manifold

3. Place engine assembly on stand.
4. Remove intake manifold collector.






5. Disconnect injector harness connector and remove fuel tube assembly with injector.
- Do not disassemble fuel hose.

6. Remove intake manifold.
7. Remove rocker cover.






8. Set No. 1 piston at TDC on its compression stroke. Align the timing mark (orange paint) on crankshaft pulley with timing indicator on front cover.






Make sure the intake camshaft lobe for the No. 1 cylinder faces the intake port and the exhaust lobe faces the exhaust port.
Reference: It is possible to confirm camshaft positions by checking notch positions on the camshaft when No. 1 piston is at TDC of the compression stroke. This is the position where cylinder head bolts can be removed.









9. Remove crankshaft pulley.
- Do not remove the crankshaft pulley balance weight.
- Do not disassemble the crankshaft pulley.

10. Remove camshaft position sensor assembly. Do not disassemble camshaft position sensor unit.









11. Remove front cover upper.
- Loosen bolts and nuts in the numerical order shown in the image and then remove them.









12. Remove upper chain tensioner.
- Press tensioner in and insert l mm (0.04 inch) diameter pin in pin hole. After securing tensioner, remove bolts.






13. Remove camshaft sprocket bolt while holding the hexagonal part of camshaft with wrench. Remove camshaft sprockets.
- Apply paint to upper timing chain and camshaft sprockets for alignment during installation.






14. Remove right and left tensioner covers from front covers.
- Press tensioner in and insert 1 mm (0.04 inch) diameter pin in pin hole.

15. Remove idler sprocket bolts.
16. Remove chain guide between No. 1 camshaft bracket.
17. Remove cylinder head assembly.
18. Remove upper timing chain.
19. Remove idler sprocket.
- Apply paint to lower timing chain and idler sprocket for alignment during installation.

20. Remove oil pan.






21. Remove front cover. Loosen bolts in the numerical order shown in the image and then remove them.
22. Remove lower chain tensioner.
23. Remove oil pump drive chain.
24. Remove slack guide and chain guide.
25. Remove lower timing chain together with crankshaft sprocket.

INSPECTION






Check for cracks and excessive wear at roller links. Replace if necessary.