Timing Chain: Service and Repair

REMOVAL





POSITION FOR APPLYING LIQUID GASKET
- Before installation, wipe off the protruding sealant.

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. Refer to Powertrain Management; Fuel Delivery and Air Induction.
- Do not spill engine coolant on drive belts.





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 figure and then remove them.








12. Remove upper chain tensioner.
- Press tensioner in and insert 1 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 Dolts.
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 figure 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
TIMING CHAIN





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

INSTALLATION





- Refer to the figure and align the mating marks on each sprocket and timing chain.





1. Check that crankshaft key faces upward at 45° angle in direction of left bank axis when viewed from the front.





2. Install lower timing chain on right bank. Align the mating marks on timing chain and crankshaft sprocket and install on crankshaft.





3. Install crankshaft sprocket so thick boss faces cylinder block.





4. Install slack guide and chain guide.
Refer to figure and check that bolt assembly is correctly positioned.





Tightening Torque: 13 - 19 Nm (1.3 - 1.9 kg-m, 9 - 14 ft. lbs.)
5. Install lower timing chain on left bank. Align the mating marks on timing chain and crankshaft sprocket and install on crankshaft. Install crankshaft with boss side facing engine. (Install in same manner as right bank.)





6. Install left bank slack guide and chain guide. Refer to figure and make sure bolts are installed correctly.





7. Install oil pump drive chain.
- Install oil pump drive sprocket on crankshaft side with boss side facing cylinder block.





8. Install the upper and lower oil pump drive chain guides. Install the upper guide as follows.
a. Install the lower side.
b. Loosely tighten bolts on upper side.
c. Insert 1 mm (0.04 inch) feeler gauge between guide and chain. Press the guide lightly on the chain side with the same force as the guide weight and tighten installation bolts.
6.3 - 8.3 Nm (0.64 - 0.85 kg-m, 55.6 - 73.8 inch lbs.)





9. Install chain tensioner.
- Always replace gasket with new part.
- Install gasket by pressing the notch on pin connecting chain tensioner to plate.
Be careful not to bend gasket during installation.
- Install with pins inserted.
Tighten bolts to specified tightening torque. 9.2 - 10.8 Nm (0.94 - 1.1 kg-m, 81.6 - 95.5 inch lbs.)
- Lubricate timing chain and sliding parts with engine oil.
10. Install front cover.
- Apply liquid gasket to front cover.





- Tighten bolts in the numbered order shown in the figure.





- The bolt dimensions and tightening torque vary depending on the position. Refer to the table for the correct procedure.
Before installing front cover, make sure crankshaft sprocket and timing chain mating marks have not become misaligned.
11. Coat idler shaft with engine oil and install on idler sprocket.





12. Align the mating marks on the lower timing chains with idler sprocket mating marks and install.





13. Set upper timing chains on idler sprockets and rotate them.

NOTE: It is not necessary to align the positions of the upper chain and idler sprocket at this time because the mating mark can be aligned after the cylinder head is installed.

14. Install cylinder head gasket and cylinder head assembly.





15. Align mating marks on idler sprocket and upper timing chain. Install on camshaft without changing positioning.





16. Install idler shaft bolts.
Tightening Torque: 43 - 58 Nm (4.4 - 5.9 kg-m, 32 - 43 ft. lbs.)
- Install washer so chamfered side faces front of engine.





17. Remove lower chain tensioner pin from tensioner cover holes on front cover.
18. Install tensioner cover.
- Apply liquid gasket to front cover.
19. Install chain guide between No. 1 camshaft bracket.
20. Install camshaft sprockets.





a. Identify the camshaft sprocket type. The intake side camshaft sprockets can be identified by the difference in the "l", dimension shown in the figure. "a" dimension:
Right bank 15.2 mm (0.598 inch)
Left bank 10.2 mm (0.402 inch)





- The same type of cam sprockets are used for both left and right banks. Only the positioning direction changes. When installing, position camshaft sprockets on both right and left banks facing the side with "R" / "L" punchmarks toward front of engine, respectively.





b. Align the upper timing chain mating marks with sprocket mating marks (The notch is only used as a mating mark for the left bank exhaust side. Punchmarks are used in the other positions.) and install on camshaft.
If the sprocket does not fit on camshaft dowel pin, turn the hexagonal part of the camshaft with a wrench to align.
- Make sure the timing chain and idler sprocket mating marks do not become misaligned during the installation operation.





c. Install camshaft sprocket bolts.
Position the washers for the intake and exhaust so chamfered side forward.
Lubricate the thread of exhaust bolt and seating surface with engine oil.





d. Tighten camshaft sprocket bolts.
Tighten sprocket bolts to specified torque while holding the hexagonal part of camshaft.
Intake:
Tightening Torque: 103 - 113 Nm (10.5 - 11.5 kg-m, 76 - 83 ft. lbs.)
Exhaust:
Tightening Torque: 16 - 21 Nm (1.6 - 2.1 kg-m, 12 - 15 ft. lbs.)





21. Install chain tensioner.
- Press chain tensioner in and insert 1 mm (0.04 inch) diameter pin in pin hole to secure tensioner and then install tensioner. Reference: Reuse the accessory pin when replacing the chain tensioner with a new part.
Tighten bolts to specified torque.
Tightening Torque: 9.2 - 10.8 Nm (0.94 - 1.1 kg-m, 81.6 - 95.5 inch lbs.)
Remove pin after installation is completed.
- Install chain tensioner guide in the direction shown in the figure.
22. Lubricate timing chain and chain sliding parts with new engine oil.








23. Install front cover upper.
- Apply liquid gasket to front cover upper.
- Install bolts in the numerical order shown in the figure.
Tightening Torque: 6.3 - 8.3 Nm (0.64 - 0.85 kg-m, 55.6 - 73.8 inch lbs.)
Before installing cover, check that timing chain and sprocket mating marks are aligned correctly.
- Install chain guide bolt on front cover upper.





24. Install camshaft position sensor.

NOTE: Notch on exhaust camshaft on left bank is off-centered so that camshaft position sensor can be installed properly.

25. Install crankshaft pulley.





26. 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.





27. Install oil pan.
28. Install rocker cover.





29. Install intake manifold.
- Tighten bolts in numerical order as shown in the figure.





30. Install fuel tube assembly.
- Tighten in numerical order as shown in the figure.
a. Tighten all bolts to 9.3 to 10.8 Nm (0.95 to 1.1 kg-m, 6.9 to 8.0 ft. lbs.).
b. Tighten all bolts to 21 to 26 Nm (2.1 to 2.7 kg-m, 15 to 20 ft. lbs.).





31. Install intake manifold collector.
- Tighten in numerical order as shown in the figure.





32. Install exhaust manifolds.