Timing Chain: Service and Repair
REPLACEMENT1. REMOVE HOOD SUB-ASSEMBLY
2. REMOVE FRONT WHEEL RH
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT FENDER APRON SEAL RH
6. DRAIN ENGINE OIL
a. Install a new gasket and the drain plug after draining engine oil.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
7. REMOVE EXHAUST PIPE ASSEMBLY FRONT
8. REMOVE ENGINE MOVING CONTROL ROD W/ BRACKET
a. Remove the 3 bolts and engine moving control rod w/ bracket.
9. REMOVE ENGINE MOUNTING STAY NO. 2 RH
10. REMOVE ENGINE MOUNTING BRACKET NO. 2 RH
11. REMOVE FAN AND GENERATOR V BELT
12. REMOVE ENGINE COVER SUB-ASSEMBLY NO.
13. DISCONNECT ENGINE WIRE
14. REMOVE GENERATOR ASSEMBLY
15. REMOVE VANE PUMP ASSEMBLY
NOTICE: Do not disconnect the hose.
16. REMOVE IGNITION COIL ASSEMBLY
17. DISCONNECT VENTILATION HOSE
18. DISCONNECT VENTILATION HOSE NO. 2
19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the bolt and disconnect the engine wire harness clamp.
b. Remove the 8 bolts and 2 nuts, and disconnect the cylinder head cover.
20. SET NO. 1 CYLINDER TO TDC/COMPRESSION
21. REMOVE CRANKSHAFT PULLEY
a. Remove the crankshaft pulley (TMC made).
1) Using SST, loosen the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00002
2) Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
b. Remove the crankshaft pulley (TMMK made).
1) Using SST, loosen the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
2) Using SST, remove the crankshaft pulley.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010, 91111-51014)
22. REMOVE CRANK POSITION SENSOR
23. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 12 bolts and 2 nuts.
b. Insert the blade of SST between the crankcase and oil pan, cut off 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.
24. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1
a. Remove the 2 nuts, timing chain tensioner and gasket.
NOTICE: Be sure not to revolve the crankshaft without the chain tensioner.
25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, the bolt and drive belt tensioner.
26. INSTALL ENGINE HANGER NO. 1
a. Install the engine hanger No. 1, No. 2 and bolt as shown in the illustration.
Torque: 38 Nm (387 kgf-cm, 30 ft. lbs.)
Parts No.:
Engine hanger No.1 12281-28010
Engine hanger No.2 12282-28010
Bolt 91512-061020
27. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
a. Attach the engine chain hoist to the engine hangers.
CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
b. Remove the bolt, and disconnect the engine mounting insulator.
c. Remove the bolt and disconnect the engine lateral control rod (M/T).
d. Remove the bolt and disconnect the steering gear return hose clamp from the frame.
e. Remove the 4 nuts from the engine mounting insulator RH.
f. Raise the engine and remove the engine mounting insulator RH.
28. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 3 bolts and the engine mounting bracket RH.
29. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the stud bolt for drive belt tensioner from the cylinder block.
b. Remove the 14 bolts and 2 nuts.
c. Remove the timing chain cover with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of timing chain cover, cylinder block and cylinder head.
30. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
31. REMOVE CHAIN TENSIONER SLIPPER
32. REMOVE CHAIN VIBRATION DAMPER NO. 1
33. REMOVE CHAIN SUB-ASSEMBLY
34. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
35. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
a. Turn the crankshaft counterclockwise 90°, and align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
b. Put a bar ([diameter] 4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut.
c. Remove the bolt, chain tensioner plate and spring.
d. Remove the chain tensioner, oil pump drive shaft gear and No. 2 chain.
36. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
a. Set the crankshaft key into the left horizontal position.
b. Turn the cutout of the drive shaft to the top.
c. Align the mark links (yellow colored links) with the timing marks of the gear as shown in the illustration.
d. Insert the gears with chain to the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump drive shaft gear by a nut.
f. Inset the damper spring into the adjusting hole, and install the chain tensioner plate by a nut.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
g. Align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
h. Put a bar ([diameter] 4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and assemble a nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)
i. Rotate the crankshaft clockwise 90°, and align the crankshaft key to the top.
37. INSTALL CHAIN VIBRATION DAMPER NO. 1
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
38. INSTALL CHAIN SUB-ASSEMBLY
a. Set No. 1 cylinder to TDC/compression.
1) Align the timing marks of the camshaft timing sprockets with No. 1 bearing caps.
2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
b. Align the mark link (gold or orange colored link) with the timing mark of the crankshaft timing gear.
c. Using a SST, install the sprocket.
SST 09309-37010
d. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
39. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
40. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
a. Install the crankshaft position sensor plate the "F" mark facing forward.
41. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes after applying seal packing.
- Do not start the engine 2 hours after installing.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
b. Apply seal packing in the shape of bead (Diameter 2 mm (0.099 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.118 - 0.157 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
d. Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 Nm (92 kgf-cm, 80 inch lbs.)
Bolt B 21 Nm (214 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.)
Nut 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Install the stud bolt to the drive belt tensioner.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
42. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the drive belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft. lbs.)
43. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
44. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
a. Raise the engine and install the engine mounting insulator RH.
b. Install the engine mounting insulator RH with the 4 nuts.
Torque:
Bolt A 95 Nm (969 kgf-cm, 70 ft. lbs.)
Bolt B 87 Nm (888 kgf-cm, 64 ft. lbs.)
c. Install the bolt and disconnect the steering gear return hose clamp from the frame.
Torque: 8.0 Nm (80 kgf-cm, 69 inch lbs.)
d. Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (888 kgf-cm, 64 inch lbs.)
e. Install the engine lateral control rod with the bolt (M/T).
Torque: 89 Nm (910 kgf-cm, 69 inch lbs.)
45. INSTALL OIL PAN SUB-ASSEMBLY
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not start the engine 2 hours after installing.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the cylinder block and oil pan.
b. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.157 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
46. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
47. INSTALL CRANK POSITION SENSOR
a. Install the bolt and crankshaft position sensor.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Confirm the wire harness of the crank position sensor is placed as shown in the illustration.
48. INSTALL CRANKSHAFT PULLEY
a. Install the crankshaft pulley (TMC made).
1) Align the pulley set key with the key groove of the pulley, and side on the pulley.
SST 09213-54015 (91651-60855), 09330-00021
2) Using SST, install the pulley bolt.
Torque: 170 Nm (1,733 kgf-cm, 125 ft. lbs.)
b. Install the crankshaft pulley (TMMK made).
1) Align the pulley set key with the key groove of the pulley, and side on the pulley.
SST 0996-10010 (09962-1000, 09963-01000)
2) Using SST, install the pulley bolt.
Torque: 170 Nm (1,733 kgf-cm, 125 ft. lbs.)
c. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
d. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
50. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
51. INSTALL VANE PUMP ASSEMBLY
52. INSTALL GENERATOR ASSEMBLY
53. INSTALL ENGINE WIRE
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)
56. INSTALL ENGINE MOUNTING STAY NO. 2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
54. INSTALL FAN AND GENERATOR V BELT
55. INSTALL ENGINE MOUNTING BRACKET NO. 2 RH
57. INSTALL ENGINE MOVING CONTROL ROD W/ BRACKET
a. Install the engine mounting control rod w/ bracket with 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
58. INSTALL EXHAUST PIPE ASSEMBLY FRONT
59. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
60. INSTALL HOOD SUB-ASSEMBLY
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
61. ADD ENGINE OIL
62. INSPECT OIL LEAK