Timing Cover: Service and Repair
FRONT TIMING CHAIN CASERemoval and Installation
NOTE:
^ This section describes removal/installation procedure of front timing chain case and timing chain (primary) related parts without removing oil pan (upper) on vehicle.
^ When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain (primary) related parts, and rear timing chain case in this order, and install in the reverse order of removal.
REMOVAL
1. Remove engine cover with power tool.
2. Release the fuel pressure.
3. Drain engine oil.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine oil on drive belts.
4. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
5. Separate engine harnesses removing their brackets from front timing chain case.
6. Remove radiator cooling fan assembly.
7. Remove drive belts.
8. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
9. Remove power steering oil pump bracket.
10. Remove alternator.
11. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
12. Remove right and left intake valve timing control covers. (A/T models)
^ Loosen bolts in reverse order as shown in the figure.
^ Use seal cutter [SST: KV10111100 (J37228)] or an equivalent tool to cut liquid gasket for removal.
CAUTION: Shaft is internally jointed with intake camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected.
13. Remove left and right valve timing control covers (including magnet retarder and cover) with the following procedure. (M/T models)
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Shaft is engaged with intake side camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged.
^ The mating surface of magnet retarder may be fitted with the exhaust side camshaft sprocket via the engine oil. Open valve timing control cover carefully.
^ If the mating surface of magnet retarder is fitted with the camshaft sprocket, open the cover within the range that the load is not applied to the harness. And then, remove it so as to prevent magnet retarder from dropping.
CAUTION:
^ Be careful not to damage magnet retarder.
^ When carrying valve timing control cover, face the magnet retarder side up to prevent the cover from falling from magnet retarder.
^ Do not remove magnet retarder from valve timing control cover. (Disassembly prohibited parts)
14. Remove collared O-ring from front timing chain case (left and right side). (A/T models)
15. Remove rocker covers (right and left banks) with power tool.
NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed.
16. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE: When timing chain is not removed/installed, this step is not required.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
b. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure.
^ If not, turn crankshaft one revolution (360°) and align as shown in the figure.
NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets.
17. Remove crankshaft pulley as follows:
a. Remove starter motor (2WD) or rear plate cover (AWD) and set ring gear stopper [SST] as shown in the figure.
NOTE: Figure shows 2WD models.
b. Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 inch) from its original position.
CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through.
CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
18. Remove oil pan (lower).
19. Loosen two mounting bolts in front of oil pan (upper) in reverse order as shown in the figure.
20. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
NOTE: Figure shows A/T models.
b. Insert suitable tool into the notch at the top of the front timing chain case as shown (1).
c. Pry off case by moving tool as shown (2).
^ Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.
CAUTION:
^ Do not use screwdriver or something similar.
^ After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
21. Remove O-rings from rear timing chain case.
NOTE: Figure shows A/T models.
22. Remove oil pan gasket.
23. Remove water pump cover and chain tensioner cover from front timing chain case.
^ Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.
24. Remove front oil seal from front timing chain case using suitable tool.
^ Use screwdriver for removal.
CAUTION: Be careful not to damage front timing chain case.
25. Remove timing chain (primary) and related parts.
26. Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces.
CAUTION: Be careful not to allow gasket fragments to enter oil pan.
^ Remove old liquid gasket from bolt hole and thread.
27. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
INSTALLATION
1. Install timing chain (primary) and related parts.
2. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
3. Install front oil seal on the front timing chain case. Apply new engine oil to the oil seal lip, dust seal lip and outer round of oil seal.
^ Install it so that each seal lip is oriented as shown in the figure.
^ Using suitable drift [outer diameter: 60 mm (2.36 inch)], press-fit oil seal until it becomes flush with front timing chain case end face.
^ Make sure the garter spring is in position and seal lip is not inverted.
4. Install water pump cover and chain tensioner cover to front timing chain case.
^ Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
5. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case back side as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
NOTE: Figure shows A/T models.
b. Install new oil pan gasket (front).
^ Apply liquid gasket to oil pan gasket (front) as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent.
^ Align notch of front timing chain case with protrusion of oil pan gasket.
^ Apply liquid gasket to top surface of oil pan (upper) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent.
c. Install new O-rings on rear timing chain case.
NOTE: Figure shows A/T models.
d. Assemble front timing chain case as follows:
i. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely.
CAUTION: Be careful that oil pan gasket is in place.
ii. Since front timing chain case is offset for difference of bolt holes, tight bolts temporarily with holding front timing chain case from front and top as shown in the figure.
iii. Same as the step ii, insert dowel pin with holding front timing chain case from front and top completely.
e. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
^ There are two type of mounting bolts. Refer to the following for locating bolts.
M8 bolts: 1, 2: 25.5 - 31.3 Nm (2.6 - 3.2 kg-m, 19 - 23 ft. lbs.)
M6 bolts: Except the above: 11.7 - 13.7 Nm (1.2 - 1.4 kg-m, 9 - 10 ft. lbs.)
NOTE: Figure shows A/T models.
f. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
6. Install two mounting bolts in front of oil pan (upper) in numerical order as shown in the figure.
Torque: 15.7 - 18.6 Nm (1.6 - 1.9 kg-m, 12 - 13 ft. lbs.)
7. Install oil pan (lower).
8. Install right and left intake valve timing control covers as follows. (A/T models)
a. Install seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to intake valve timing control covers as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent.
c. Install new collared O-rings in front timing chain case oil hole (left and right sides).
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers.
e. Tighten mounting bolts in numerical order as shown in the figure.
9. Install right and left valve timing control covers as follows. (M/T models)
a. Install new seal rings in shaft grooves.
b. Install magnet retarder aligning the dowel pins of the back with the cover side dowel pin holes securely. Simultaneously insert the harness into the installation groove securely.
NOTE: Figure shows the structure of the parts. Therefore, magnet retarder is being removed from the cover in this figure. But, if magnet retarder is in the correct position, omit step "b" and perform step "c".
c. To check the joint between dowel pins and dowel pin holes, check the looseness in the axle direction by pushing the mating surface of magnet retarder at several places and the circumferential looseness (between dowel pins and dowel pin holes) by twisting in the circumferential direction.
CAUTION: Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose.
d. Install valve timing control cover to front timing chain case.
CAUTION:
^ Do not face the magnet retarder side down to prevent magnet retarder from dropping.
^ Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign materials.
^ Align the center of both shaft holes of the shaft and the intake side camshaft sprocket, and then insert them.
^ Be careful not to drop the seal ring from the shaft groove.
^ When setting the valve timing control cover in position by hand, if valve timing control cover is not contacting with the front timing chain case, the dowel pin of magnet retarder may not be aligned with the dowel pin holes of cover. In this case, return to step "b".
e. Tighten mounting bolts in numerical order as shown in the figure.
CAUTION: Completely tighten the mounting bolts with the seat surface of valve timing control cover contacting with the front timing chain.
10. Install crankshaft pulley as follows:
a. Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)].
b. Install crankshaft pulley, taking care not to damage front oil seal.
^ When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). c. Tighten crankshaft pulley bolt.
Torque: 44.1 Nm (4.5 kg-m, 33 ft. lbs.)
d. Turn crankshaft pulley bolt 90° clockwise (angle tightening).
CAUTION:
^ Check the tightening angle by using the angle wrench [SST]. Avoid judgement by visual inspection without SST.
^ Check tightening angle indicated on the angle wrench indicator plate.
11. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
12. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluid leak, lubricates leak and exhaust gases leak.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
^ Run engine to check for unusual noise and vibration.
NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
^ Warm up engine thoroughly to make sure there is no leakage of exhaust gases, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
Summary of the inspection items:
