Infinity_FX35_FX45_2003-2005

Timing Chain & Sprockets (1 of 2)

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Removal & Installation



3.5L Engine


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Fig. Exploded view of timing chain and related components-3.5L engine



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Fig. Tightening sequence for the timing control covers-3.5L engine



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Fig. O-ring location in the front timing chain case-3.5L engine



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Fig. Ring gear stopper positioning-3.5L engine



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Fig. Tightening sequence for the front timing chain case mounting bolts-3.5L engine



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Fig. Pry off the front timing chain case as shown-3.5L engine



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Fig. O-ring positions in rear timing chain case-3.5L engine



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Fig. Timing chain tensioner detail-3.5L engine



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Fig. Internal chain guide, tension guide and slack guide positions-3.5L engine



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Fig. Secondary timing chain tensioner positions-3.5L engine



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Fig. Secondary timing chain plunger setting for removal-3.5L engine



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Fig. Cross-section of intake camshaft sprocket-Do NOT loosen bolts A or B-3.5L engine



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Fig. Tightening sequence for the rear timing chain case mounting bolts-3.5L engine



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Fig. Do not remove these plate metal covers-3.5L engine



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Fig. Cylinder head O-ring positions-3.5L engine



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Fig. Alignment marks for timing chain installation-3.5L engine



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Fig. Liquid gasket positions for timing chain case installation-3.5L engine



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Fig. Check the surface height difference between the rear timing chain case and the cylinder block-3.5L engine



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Fig. Camshaft positioning for timing chain installation-3.5L engine



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Fig. Secondary timing chain installation alignment-3.5L engine



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Fig. Intake camshaft sprocket and secondary timing chain alignment-3.5L engine



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Fig. Crankshaft sprocket installation position-3.5L engine



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Fig. Primary and secondary timing chain installation positioning-3.5L engine



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Fig. A gap between the slack guide bolt head and the slack guide is normal-3.5L engine



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Fig. Crankshaft oil seal installation positioning-3.5L engine



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Fig. Chain tensioner cover liquid gasket positioning-3.5L engine

With Oil Pan Removal
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  

This section describes procedures for removing/installing the front timing chain case and timing chain related parts, and the rear timing chain case, when the upper oil pan needs to be removed/installed for engine overhaul, etc.

When the upper oil pan needs to be removed or installed, or when rear timing chain case is removed or installed, remove the oil pans (upper and lower) first. Then remove the front timing chain case, timing chain related parts, and the rear timing chain case in this order, and install in the reverse order of removal.

  1. Place the vehicle on a lift.
  2.  
  3. Remove the front tire.
  4.  
  5. Disconnect the negative battery terminal.
  6.  
  7. Remove the engine cover.
  8.  
  9. Remove the air cleaner case assembly.
  10.  
  11. Remove the front and rear engine under covers.
  12.  
  13. Drain the engine coolant from the radiator.
  14.  
  15. Drain the engine oil from the oil pan.
  16.  
  17. Remove the engine wiring harnesses.
  18.  
  19. Remove the upper and lower intake manifold collectors.
  20.  
  21. Remove the radiator cooling fan assembly.
  22.  
  23. Remove the A/C compressor from the bracket with its piping connected, and temporarily secure it aside.
  24.  
  25. Remove the power steering oil pump from the bracket with its piping connected, and temporarily secure it aside.
  26.  
  27. Remove the power steering oil pump bracket.
  28.  
  29. Remove the alternator.
  30.  
  31. Remove the water bypass hose, water hose clamp and idler pulley bracket from the front timing chain case.
  32.  
  33. Remove the upper and lower oil pan.
  34.  
  35. Remove the right and left intake valve timing control covers, by loosening the bolts in the reverse or the tightening sequence.
  36.  
  37. Use a seal cutter to cut the liquid gasket for removal.
    CAUTION
    The shaft is internally joined to the intake camshaft sprocket center hole. During removal, keep the shaft horizontal until it is completely disconnected.

  38.  
  39. Remove the collared O-ring from the front timing chain case (left and right side).
  40.  
  41. Remove the right and left rocker covers.
  42.  
  43. Position the engine at compression TDC of No. 1 cylinder as follows:
    1. Rotate the crankshaft pulley clockwise to align the timing mark (grooved line without color) with the timing indicator.
    2.  
    3. Make sure the intake and exhaust cam noses on the No. 1 cylinder (engine front side of right bank) are located so that they point inward and upward compared to the cylinder head.
    4.  
    5. If the cam lobes are not positioned pointing inward and upward, rotate the crankshaft one full revolution (360 degrees).
    6.  

  44.  
  45. Remove the crankshaft pulley, as follows:
    1. For 2WD models, remove the rear cover plate.
    2.  
    3. For AWD models, remove the starter motor.
    4.  
    5. Set the ring gear stopper to hold the crankshaft in position.
    6.  
    7. Loosen the crankshaft pulley bolt until the bolt seating surface is approximately 0.39 in. (10mm) from its original position.
      CAUTION
      Do not completely remove the crankshaft pulley bolt, since it will be used as a supporting point for a suitable puller.

    8.  
    9. Place a suitable puller tab on the holes of the crankshaft pulley, and pull the crankshaft pulley through.
      CAUTION
      Do not position the suitable puller tab on the outer edges of the crankshaft pulley since this can damage the internal damper.

    10.  

  46.  
  47. Remove the front timing chain case, as follows:
    1. Loosen the mounting bolts in the reverse order of the tightening sequence.
    2.  
    3. Insert the suitable tool into the notch at the top of the front timing chain case.
    4.  
    5. Pry off the case by moving the pry tool as shown. Use a seal cutter to cut the liquid gasket for removal.
      CAUTION
      Do not use a screwdriver or similar, since it may damage the mating surfaces. And after removal, handle it carefully so that it does not tilt, cant, or warp under a load.

    6.  

  48.  
  49. Remove the O-rings from the rear timing chain case.
  50.  
  51. Remove the water pump cover and chain tensioner cover from the front timing chain case. Use the seal cutter, or equivalent, to cut the liquid gasket for removal.
  52.  
  53. Remove the front oil seal from the front timing chain case using a suitable tool.
    CAUTION
    Be careful not to damage the front timing chain case.

  54.  
  55. Remove the primary timing chain tensioner, as follows:
    1. Pull the lever down and release the plunger stopper tab. The plunger stopper tab can be pushed up to release.
    2.  
    3. Insert a stopper pin into the tensioner body hole to hold the lever, and keep the tab released.
      NOTE
      A 0.098 in. (2.5mm) Allen wrench can be used for a stopper pin.

    4.  
    5. Insert the plunger into the tensioner body by pressing on the slack guide.
    6.  
    7. Keep the slack guide depressed and hold it by pushing the stopper pin through the lever hole and body hole.
    8.  
    9. Remove the mounting bolts and remove the primary timing chain tensioner.
    10.  

  56.  
  57. Remove the internal chain guide, tension guide and slack guide.
    NOTE
    The tension guide can be removed after removing the primary timing chain.

  58.  
  59. Remove the primary timing chain, tension guide and crankshaft sprocket.
    CAUTION
    After removing the timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike piston heads.

  60.  
  61. Remove the secondary timing chain and camshaft sprockets, as follows:
    1. Attach a suitable stopper pin to the right and left secondary timing chain camshaft chain tensioners.
    2.  
    3. Remove the intake and exhaust camshaft sprocket bolts. Apply paint to the timing chain and camshaft sprockets for alignment during installation. Secure the hexagonal portion of the camshaft using an open-end wrench to hold the camshaft steady while loosening the mounting bolts.
    4.  
    5. Remove the secondary timing chain together with camshaft sprockets. Turn the camshaft slightly to create slack in the timing chain on the secondary timing chain tensioner side. Insert a 0.020 in. (0.5mm) thick metal or resin plate between the timing chain and timing chain tensioner plunger guide. Remove the secondary timing chain together with the camshaft sprockets with the timing chain loose from the guide groove.
      CAUTION
      Be careful of the plunger coming-off when removing the secondary timing chain. This is because the plunger of the secondary timing chain tensioner moves during operation, which can result in the fixed stopper pin coming off.


      NOTE
      Camshaft sprocket (INT) is a two-for-one assembly of the primary and secondary sprockets.


      CAUTION
      When handling the camshaft sprocket (INT), be careful of the following:



      Handle it carefully to avoid any shock to the camshaft sprocket.
       
      Do not disassemble. Do not loosen bolts A and B.
       

    6.  

  62.  
  63. Remove the rear timing chain case, as follows:
    1. Loosen and remove the mounting bolts in the reverse order of the tightening sequence.
    2.  
    3. Cut the sealant using a seal cutter and remove the rear timing chain case.
      CAUTION
      Do not remove plate metal cover of engine oil passage. After removing the chain case, do not apply any load on the case which could affect flatness.

    4.  

  64.  
  65. Remove the O-rings from the cylinder head.
  66.  
  67. Remove the O-rings from the cylinder block.
  68.  
  69. If necessary, remove the secondary timing chain tensioners from the cylinder head, as follows:
    1. Remove the No. 1 camshaft brackets.
    2.  
    3. Remove the secondary timing chain tensioners with the stopper pins attached.
    4.  

  70.  
  71. Use a scraper to remove all traces of liquid gasket from the front and rear timing chain cases, and opposite mating surfaces.
    CAUTION
    Be careful not to allow gasket fragments to enter the oil pan.

  72.  
  73. Remove the old liquid gasket from the bolt holes and threads.
  74.  
  75. Use a scraper to remove all traces of liquid gasket from the water pump cover, chain tensioner cover and intake valve timing control covers.
  76.  
  77. Inspect the timing chain for cracks and any excessive wear at link plates and roller links of the timing chain. Replace the timing chain, as necessary.
  78.  

To install:


NOTE
The accompanying illustration shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.

  1. If removed, install the secondary timing chain tensioners on the cylinder head, as follows:
    1. Install the chain tensioners with stopper pins attached and new O-rings.
    2.  
    3. Install the No. 1 camshaft brackets. Refer to the camshaft removal and installation procedure.
    4.  

  2.  
  3. Install new O-rings onto the cylinder block.
  4.  
  5. Install new O-rings on the cylinder head.
  6.  
  7. Apply liquid gasket to the rear timing chain case backside, as shown.
    CAUTION
    Use Genuine RTV Silicone Sealant or equivalent.

  8.  
  9. For A in the illustration, completely wipe out the liquid gasket extended on a portion touching at engine coolant.
  10.  
  11. Apply liquid gasket on the installation position of the water pump and cylinder head completely.
  12.  
  13. Align the rear timing chain case and water pump assembly with right and left dowel pins on cylinder block and install the case.
    NOTE
    Make sure the O-rings stay in place during installation on the cylinder block and cylinder head.

  14.  
  15. Tighten the mounting bolts in the sequence shown. After all bolts are temporarily tightened, retighten them to 9 ft. lbs. (13 Nm) in the tightening sequence.
    NOTE
    There are two bolt lengths used for the timing chain case:


    NOTE
    If RTV Silicone Sealant protrudes, wipe it off immediately.



    20mm length: Pos. 1, 2, 3, 6, 7, 8, 9, 10
     
    16mm length: Except Pos. 1, 2, 3, 6, 7, 8, 9, 10
     

  16.  
  17. After installing the rear timing chain case, check the surface height difference between the rear timing chain case to the cylinder block at the oil pan mounting surface. If the difference is not within - 0.0094 - 0.0055 in. ( - 0.24 - 0.14 mm), repeat the installation procedure.
  18.  
  19. Position the crankshaft so the No. 1 piston is set at TDC on the compression stroke. Make sure that the dowel pin hole, dowel pin and crankshaft key are located as shown.
    NOTE
    Though the camshaft does not stop at the position as shown in the figure, for the placement of the cam nose, it is generally accepted the camshaft is placed in the same direction of the figure and as follows:


    CAUTION
    The hole on the small diameter side must be used for the intake side dowel pin hole. Do not misidentify (ignore the big diameter side).



    Camshaft dowel pin hole (intake side): At the cylinder head upper face side in each bank.
     
    Camshaft dowel pin (exhaust side): At the cylinder head upper face side in each bank.
     
    Crankshaft key: At the cylinder head side of the right bank.
     

  20.  
  21. Install the secondary timing chains and camshaft sprockets, as follows:
    CAUTION
    The matching marks between the timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.

    1. Push the plunger of the secondary chain tensioner and keep it pressed in with a stopper pin.
    2.  
    3. Install the secondary timing chains and camshaft sprockets. Align the mating marks on the secondary timing chain (gold link) with the ones on the intake and exhaust camshaft sprockets (stamped), and install them.
    4.  

  22.  
  23. Ensure that the sprockets are properly positioned by heeding the following items:

    The mating marks for the intake camshaft sprocket are on the back side of the secondary camshaft sprocket.
     
    There are two types of mating marks, circle and oval types. They should be used for the right and left banks, respectively. For the right bank, use the circle type of mating mark, and for the left bank use the oval type of mating mark.
     
    Align the dowel pin and pin hole on the camshaft with the groove and dowel pin on the sprocket, and install them.
     
    On the intake side, align the pin hole on the small diameter side of the camshaft front end with the dowel pin on the back side of camshaft sprocket, and install them.
     
    On the exhaust side, align the dowel pin on the camshaft front end with the pin groove on the camshaft sprocket, and install them.
     
    In the case that positions of each mating mark and each dowel pin are not fit on the mating parts, make fine adjustments to the position holding the hexagonal portion of the camshaft with a wrench or equivalent.
     
    Mounting bolts for the camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins.
     
    It may be difficult to visually check the dislocation of the mating marks during and after installation. To make the matching easier, make a mating mark on the top of the sprocket teeth and its extended line in beforehand with paint.
     

  24.  
  25. After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts, while securing the camshaft using a wrench on a hexagonal portion of the camshaft.
  26.  
  27. Pull the stopper pins out from the secondary timing chain tensioners.
  28.  
  29. Install the primary timing chain, as follows:
    NOTE
    During alignment, be careful to prevent dislocation of the mating mark alignments of the secondary timing chains.

    1. Install the crankshaft sprocket, making sure the mating marks on the crankshaft sprocket face the front of the engine.
    2.  
    3. Install the primary timing chain, so that the mating mark (punched) on the camshaft sprocket is aligned with the yellow link on the timing chain, while the mating mark (notched) on the crankshaft sprocket is aligned with the orange one on the timing chain, as shown.
      NOTE
      If it is difficult to align mating marks of the primary timing chain with each sprocket, gradually turn the camshaft using a wrench on the hexagonal portion of the camshaft to align it with the mating marks.

    4.  

  30.  
  31. Install the internal chain guide and primary timing chain tensioner.
  32.  
  33. Install the slack guide.
    CAUTION
    Do not over tighten the slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when the mounting bolts are tightened to specification.

  34.  
  35. Remove all dirt and foreign materials completely from the back and mounting surfaces of the chain tensioner.
  36.  
  37. Install chain tensioner for slack guide. When installing the chain tensioner, push in the sleeve and keep it depressed with a stopper pin.
  38.  
  39. After chain tensioner installation, pull out the stopper pin by pressing in the slack guide.
  40.  
  41. Reconfirm that the mating marks on sprockets and timing chains have not slipped out of alignment.
  42.  
  43. Install new O-rings on the rear timing chain case.
  44.  
  45. Install the front oil seal on the front timing chain case, as follows:
    1. Apply new engine oil to the oil seal edges.
    2.  
    3. Make sure the garter spring is in position and the seal lip is not inverted, and so that each seal lip is oriented as shown in the figure.
    4.  
    5. Using a suitable drift, press-fit the oil seal until it is flush with the front timing chain case end face.
    6.  

  46.  
  47. Install the water pump cover and chain tensioner cover to the front timing chain case. Apply liquid gasket to the front timing chain case front side as shown.
    NOTE
    Use Genuine RTV Silicone Sealant or equivalent.

  48.  
  49. Install the front timing chain case as follows:
    1. Apply liquid gasket to front timing chain case back side as shown.
      NOTE
      Use Genuine RTV Silicone Sealant or equivalent.

    2.  
    3. Install the dowel pin on the rear timing chain case into the dowel pin hole on the front timing chain case.
    4.  
    5. Tighten the bolts to the specified torque in the order shown. Refer to the following for locating the bolts.

      8mm bolts (positions 1 & 2): 21 ft. lbs. (28 Nm)
       
      6mm bolts (except positions 1 & 2): 9 ft. lbs. (13 Nm)
       

    6.  
    7. After tightening, retighten them to the specified torque in the numerical order shown.
    8.  

  50.  
  51. After installing the front timing chain case, check the surface height difference between the front timing chain case to rear timing chain case on the oil pan mounting surface. The allowable height difference is -0.005 - 0.0055 in. ( - 0.14 - 0.14mm). If not within specification, repeat the installation procedure.
  52.  
  53. Install the right and left intake valve timing control covers, as follows:
    1. Install the seal rings in the shaft grooves.
    2.  
    3. Apply liquid gasket to the intake valve timing control covers.
      NOTE
      Use Genuine RTV Silicone Sealant or equivalent.

    4.  
    5. Install the collared O-ring in the front cover engine oil hole (left and right sides).
    6.  
    7. Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes to install the intake valve timing control covers. Tighten the bolts in the order shown.
    8.  

  54.  
  55. Install the crankshaft pulley, as follows:
    1. Fix the crankshaft in position using ring gear stopper SST: KV10117700 (J44716) or equivalent.
    2.  
    3. Install the crankshaft pulley, taking care not to damage the front oil seal.
      CAUTION
      When press-fitting the crankshaft pulley with a plastic hammer, tap on its center portion, not on the circumference.

    4.  
    5. Tighten the crankshaft bolt to 33 ft. lbs. (44 Nm).
    6.  
    7. Put a paint mark on the crankshaft pulley aligned with the angle mark on the crankshaft pulley bolt. Then, further tighten the bolt 60 degrees (equivalent to one graduation) on 2003 - 05 engines, or 90 degrees on 2006 engines.
    8.  

  56.  
  57. Rotate the crankshaft pulley in the normal direction (clockwise when viewed from front) to confirm that it turns smoothly.
  58.  
  59. The remainder of installation is the reverse of removal.
    NOTE
    If the hydraulic pressure inside the chain tensioner drops after removal/installation, the slack in the guide may generate a pounding noise during and just after engine start. However, this does not indicate a problem. The noise will stop after hydraulic pressure rises.

  60.  
  61. Perform the following once installation is complete:
    1. Before starting the engine, check the levels of the engine coolant, lubrications and working fluid. If less than required quantity, fill to the specified level.
    2.  
    3. Run the engine to check for unusual noise and vibration.
    4.  
    5. Warm up the engine thoroughly to make sure there is no leakage of engine coolant, engine oil and working fluid, fuel and exhaust gas.
    6.  
    7. Bleed air from passages in pipes and tubes of applicable lines, such as in the cooling system.
    8.  
    9. After cooling down the engine, again check the amounts of the engine coolant, engine oil and working fluid. Refill to the specified level, if necessary.
    10.  

  62.  

Without Oil Pan Removal
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  

This section describes the removal/installation procedure of the front timing chain case and timing chain related parts without removing the upper oil pan.

  1. Position the vehicle onto a lift, or support it in a safe manner so that work can be performed on the underside of the vehicle.
  2.  
  3. Disconnect the negative battery terminal.
  4.  
  5. Remove the engine cover.
  6.  
  7. Remove the air cleaner case assembly.
  8.  
  9. Remove the front and rear engine undercover.
  10.  
  11. Drain the engine coolant from the radiator.
  12.  
  13. Drain the engine oil from oil pan.
  14.  
  15. Remove and label the engine wiring harnesses.
  16.  
  17. Remove the upper and lower intake manifold collectors.
  18.  
  19. Remove the power steering oil pump from the bracket with the piping connected, then temporarily secure it aside.
  20.  
  21. Remove the power steering oil pump bracket.
  22.  
  23. Remove the alternator.
  24.  
  25. Remove the water bypass hose, water hose clamp, idler pulley bracket, and accessory drive belt tensioner from the front timing chain case.
  26.  
  27. Remove the right and left intake valve timing control covers, by loosening the bolts in the reverse order as shown.
  28.  
  29. Use a seal cutter to cut the liquid gasket.
    CAUTION
    A shaft is internally jointed with the intake camshaft sprocket center hole. When removing it, keep it horizontal until it is completely disconnected.

  30.  
  31. Remove the collared O-ring from the front timing chain case left and right sides.
  32.  
  33. Remove the right and left rocker covers.
    NOTE
    When the secondary timing chain is not removed/installed, the following step and associated sub-steps are not required.

  34.  
  35. Position the engine with cylinder No. 1 on TDC of its compression stroke, as follows:
    1. Rotate the crankshaft pulley clockwise to align the timing mark (grooved line without color) with the timing indicator.
    2.  
    3. Make sure the intake and exhaust camshaft lobes noses on the No. 1 cylinder (engine front side of right bank) are located as shown.
    4.  
    5. If not, turn the crankshaft one revolution (360 degrees) and align as shown.
      NOTE
      When only the primary timing chain is removed, the rocker cover does not need to be removed. To confirm that the No. 1 cylinder is at its compression TDC, remove the front timing chain case first. Then, check the mating marks on the camshaft sprockets.

    6.  

  36.  
  37. Remove the crankshaft pulley, as follows:
    1. Remove the rear cover plate (2WD models) or the starter motor (AWD models) and set install the ring gear stopper or equivalent as shown.
    2.  
    3. Loosen the crankshaft pulley bolt until the bolt seating surface is 0.39 in. (10mm) from its original position.
      CAUTION
      Do not remove the crankshaft pulley bolt, since it will be used as a supporting point for the pulley puller.

    4.  
    5. Place a suitable puller tab in the holes of the crankshaft pulley, and remove the crankshaft pulley.
      CAUTION
      Do not situate the puller tab on crankshaft pulley periphery, as this will damage the internal damper.

    6.  

  38.  
  39. Remove the lower oil pan.
  40.  
  41. Loosen the two mounting bolts in the front of the upper oil pan in the reverse order shown.
  42.  
  43. Remove the front timing chain case, as follows:
    1. Loosen the mounting bolts in the reverse order as shown.
    2.  
    3. Insert a suitable tool into the notch at the top of the front timing chain case, as shown.
    4.  
    5. Use a seal cutter to cut the liquid gasket for removal.
      CAUTION
      Use only an approved pry tool to remove the case.

    6.  
    7. Pry off the case.
    8.  
    9. After removal, handle the case carefully so it does not tilt, cant, or warp under a load.
    10.  

  44.  
  45. Remove the O-rings from the rear timing chain case.
  46.  
  47. Remove the water pump cover and the chain tensioner cover from the front timing chain case.
  48.  
  49. Use a seal cutter to cut the liquid gasket.
  50.  
  51. Remove front oil seal from front timing chain case using a suitable pry tool.
    CAUTION
    Exercise care not to damage the front timing chain case.

  52.  
  53. Remove the timing chain and related parts.
  54.  
  55. Use a scraper to remove all traces of old liquid gasket from the front and rear timing chain cases and upper oil pan, and liquid gasket mating surfaces. Remove the old liquid gasket from bolt holes and threads.
    CAUTION
    Be careful not to allow gasket fragments to enter the oil pan.

  56.  
  57. Use a scraper to remove all traces of liquid gasket from the water pump cover, chain tensioner cover and intake valve timing control covers.
  58.  

To install:


NOTE
Throughout the installation procedure, whenever liquid gasket is to be used make sure to use Genuine RTV Silicone Sealant or equivalent.

  1. Install the timing chain and related parts.
  2.  
  3. Hammer the dowel pins (left and left) into the front timing chain case up to a point close to the taper in order to shorten the protrusion length.
  4.  
  5. Install the front oil seal in the front timing chain case. During seal installation, heed the following:

    Apply new engine oil to the oil seal edges.
     
    Install the seal so that each seal lip is oriented as shown.
     
    Using a suitable drift, press-fit the oil seal until it becomes flush with front timing chain case end face.
     
    Make sure the retaining coil spring is in position and seal lip is not inverted.
     

  6.  
  7. Apply liquid gasket to the front timing chain case front side as shown.
  8.  
  9. Install the water pump cover and chain tensioner cover to the front timing chain case.
  10.  
  11. Install the front timing chain case, as follows:
    1. Apply liquid gasket to the front timing chain case back side as shown.
    2.  
    3. Apply liquid gasket to the oil pan gasket as shown.
    4.  
    5. Install the new oil pan gasket, and heed the following:

      Align the notch of the front timing chain case with the protrusion of the oil pan gasket.
       
      Apply liquid gasket to the top surface of the upper oil pan as shown.
       

    6.  
    7. Install new O-rings on the rear timing chain case.
      CAUTION
      Be careful that oil pan gasket is in place.

    8.  
    9. Assemble the front timing chain case by fitting the lower end of the front timing chain case tightly onto the top face of the upper oil pan. From the fitting point, make the entire front timing chain case contact the rear timing chain case completely. Then, while pressing the front timing chain case from its front and top as shown in figure, install the bolts and temporarily tighten them by hand. Hammer the dowel pin until the outer end becomes flush with the surface.
    10.  
    11. After hand tightening the mounting bolts, retighten them to specified torque in numerical order shown.
    12.  
    13. Refer to the following for locating the bolt positions and torque values:

      8mm bolts: Positions 1 & 2: 21 ft. lbs. (28 Nm)
       
      6mm bolts: Exc. positions 1 & 2: 9 ft. lbs. (13 Nm)
       

    14.  

  12.  
  13. Install two mounting bolts in the front of the upper oil pan in numerical order shown to 13 ft. lbs. (17 Nm).
  14.  
  15. Install the lower oil pan.
  16.  
  17. Install the right and left intake valve timing control covers, as follows:
    1. Install seal rings in the shaft grooves.
    2.  
    3. Apply liquid gasket to the intake valve timing control covers.
    4.  
    5. Install the collared O-ring in the front timing chain case oil hole (left and right sides).
    6.  
    7. Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes in the intake valve timing control covers.
    8.  
    9. Tighten the bolts in the numerical order shown to 8 ft. lbs. (11 Nm).
    10.  

  18.  
  19. Install the crankshaft pulley, as follows:
    1. Fix the crankshaft in position using ring gear stopper SST: KV10117700 (J44716) or equivalent.
    2.  
    3. Install the crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
    4.  
    5. Tighten the crankshaft pulley bolt to 33 ft. lbs. (44 Nm).
    6.  
    7. Put a paint mark on the crankshaft pulley aligned with the angle mark on the crankshaft pulley bolt. Then, further tighten the bolt by 60 degrees (equivalent to one graduation) for 2003 - 05 models, or 90 degrees for 2006 models.
    8.  

  20.  
  21. Rotate the crankshaft pulley in the normal direction (clockwise when viewed from the front of the engine) to confirm it turns smoothly.
  22.  
  23. The remainder of installation is the reverse of removal.
    NOTE
    If hydraulic pressure inside the 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 and the noise will stop after hydraulic pressure rises.

  24.  
  25. Perform the following once installation is complete:

    Before starting the engine, check the levels of the engine coolant, lubrications and working fluids. If less than required quantity, fill to the specified level.
     
    Run the engine to check for unusual noise and vibration.
     
    Warm up the engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid, fuel and exhaust gas.
     
    Bleed air from passages in pipes and tubes of applicable lines, such as in the cooling system.
     
    After cooling down the engine, again check the amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary.
     

  26.  

 
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