Removal & Installation
- Before servicing the vehicle, refer to the Precautions Section.
- Remove engine assembly from vehicle, and separate front suspension member, transaxle and transfer case (AWD vehicles) assembly from engine.
- Drain the engine oil.
- Remove the engine harnesses.
- Remove the water hoses.
- Remove the EVAP canister purge volume control solenoid valve.
- Remove the drive belts and idler pulley bracket.
- Remove the power steering oil pump assembly.
- Remove the alternator.
- Remove the upper and lower intake manifold collectors.
- Remove the right and left rocker covers.
Remove the crankshaft position sensor (POS).
NOTEHandle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
- Obtain compression TDC of No.1 cylinder as follows. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
- Remove lower and upper oil pans.
Remove the crankshaft pulley as follows:
- Lock crankshaft with a hammer handle or similar tool to loosen bolts.
- Remove crankshaft pulley with a suitable puller.
Remove the right and left intake valve timing control covers. Loosen bolts in reverse order as shown. Use seal cutter to cut liquid gasket for removal.
NOTEShaft is internally jointed with intake camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected.
- Remove right engine mounting bracket.
Remove front timing chain case.
- Loosen mounting bolts in reverse order as shown.
- Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1).
- Pry off the case by moving the tool as shown (2). Use seal cutter to cut liquid gasket for removal.
- Remove water pump cover and chain tensioner cover from front timing chain case. Use seal cutter to cut liquid gasket for removal.
- Remove the front oil seal from the front timing chain case using a suitable tool. Use screwdriver for removal. Exercise care not to damage front timing chain case.
- Remove internal chain guide, timing chain tensioner, tension guide and slack guide.
Remove timing chain tensioner as follows:
- Pull lever down and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever).
Insert stopper pin into tensioner body hole to hold lever, and keep the tab released.
NOTEAn Allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example.
- Insert plunger into tensioner body by pressing the slack guide.
- Keep the slack guide pressed and hold it by pushing the stopper pin through the lever hole and body hole.
- Remove the mounting bolts and remove the timing chain tensioner.
Remove timing chain (primary) and crankshaft sprocket.
NOTEAfter removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the piston heads.
- Attach a suitable stopper pin to the right and left camshaft chain tensioners (for secondary timing chains).
- Remove intake and exhaust camshaft sprocket bolts. Apply paint to timing chain and camshaft sprockets for alignment during installation. Secure the hexagonal portion of the camshaft using a wrench to loosen the mounting bolts.
Remove secondary timing chain together with camshaft sprockets. Turn camshaft slightly to secure slackness of timing chain on chain tensioner side. Insert 0.5 mm (0.020 in) thick metal or resin plate between timing chain and chain tensioner plunger (guide). Remove secondary timing chain together with camshaft sprockets from guide groove.
NOTEBe careful of plunger coming off when removing timing chain. This is because plunger of chain tensioner moves during operation, leading to coming off of fixed stopper pin.
NOTECamshaft sprocket (INT) is two-for-one structure of primary and secondary sprockets. When handling camshaft sprocket (INT), handle carefully to avoid any shock to camshaft sprocket. Do not disassemble. (Never loosen bolts -A- and -B- as shown).
- Remove chain tension guide.
- Remove the water pump.
Remove rear timing chain case as follows:
- Loosen and remove mounting bolts in reverse order as shown.
Cut the sealant using a seal cutter and remove rear timing chain case.
NOTEDo not remove plate metal cover of oil passage. After removing chain case, do not apply any load which affects flatness.
Remove right and left camshaft chain tensioners from cylinder head as follows if necessary.
- Remove No.1 camshaft brackets.
- Remove secondary chain tensioners with stopper pin attached.
- Use a scraper to remove all traces of liquid gasket from front and rear timing chain cases, and opposite mating surfaces. Remove old liquid gasket from the bolt hole and thread.
- Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.
- Check for cracks and any excessive wear at the roller links of the timing chain. Replace the timing chain as necessary.
Install right and left camshaft chain tensioners to cylinder head as follows if removed.
- Install secondary chain tensioners with stopper pin attached and new O-ring.
- Install No.1 camshaft brackets.
- Install O-rings onto cylinder block.
- Install O-rings to cylinder head.
- Apply liquid gasket to rear timing chain case back side as shown. Use RTV silicone sealant or equivalent.
Align the rear timing chain case and water pump assembly with the dowel pins (right and left) on the cylinder block and install the case. Make sure the O-rings stay in place during installation to cylinder block and cylinder head.
Tighten the mounting bolts in the numerical order as shown. There are two bolt lengths used.
Bolt length: Bolt position 20 mm (0.79 inch)
- After all bolts are temporarily tightened, retighten them to the specification in the numerical order as shown. If the RTV protrudes, wipe it off immediately.
- Tighten the mounting bolts in the numerical order as shown. There are two bolt lengths used.
- After installing rear timing chain case, check surface height difference between following parts on oil pan mounting surface. If not within standard, repeat above installation procedure.
- Install chain tension guide.
Position the crankshaft so 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.
NOTEHole on small dia. side must be used for intake side dowel pin hole. Do not misidentify.
Install the timing chains (secondary) and camshaft sprockets.
Install 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 sprockets (stamped), and install them.
NOTEMating marks for the intake 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.
- Install 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 sprockets (stamped), and install them.
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 the 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.
- Mounting bolts for the camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of the dowel pins.
- It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint.
- After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts. Secure the camshaft using a wrench at the hexagonal portion to tighten the mounting bolts.
- Pull the stopper pins out from the secondary timing chain tensioners.
Install the primary timing chain as follows:
- Install the crankshaft sprocket. Make sure the mating marks on the crankshaft sprocket face the front of the engine.
- Install the primary timing chain. Install primary timing chain so the mating mark (punched) on 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.
- When 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 to align it with the mating marks.
- During alignment, be careful to prevent dislocation of mating mark alignments of the secondary timing chains.
- Install the internal chain guide and tension guide.
- Install slack guide. 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.
- Install chain tensioner for slack guide. When installing the chain tensioner, push in the sleeve and keep it pressed in with the stopper pin. Remove any dirt and foreign materials completely from the back and the mounting surfaces of the chain tensioner. After installation, pull out the stopper pin by pressing the slack guide.
- Reconfirm that the mating marks on the sprockets and the timing chain have not slipped out of alignment.
- Install new O-rings on the rear timing chain case.
- Install the front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges. Install it so that each seal lip is oriented as shown in illustration. Using a suitable drift, press-fit oil seal until it becomes flush with timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.
- Install the water pump cover and the chain tensioner cover to front cover. Apply RTV silicone sealant.
Install front timing chain case as follows:
- Apply liquid gasket to front timing chain case back side as shown.
- Install dowel pin on the rear timing chain case into dowel pin hole on front timing chain case.
Tighten bolts to the specified torque in order shown in the illustration.
8 mm (0.31 in) dia. bolts 1, 2: 25.5-31.3 Nm (19-23 ft. lbs.)
- After tightening, retighten them to specified torque in numerical order shown in illustration.
- After tightening, retighten them to specified torque in numerical order shown in illustration.
- After installing the front timing chain case, check the surface height difference between the following parts on the oil pan mounting surface. If not within specification, repeat the installation procedure.
Install right and left intake valve timing control covers as follows:
- Install seal rings in shaft grooves.
- Apply liquid gasket to the intake valve timing control covers. Use RTV Silicone Sealant.
- Install collared O-ring in front cover oil hole (left and right sides).
- 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 bolts in the numerical order as shown.
- Install right and left rocker covers.
Install crankshaft pulley as follows:
- Fix crankshaft using a hammer shaft or an equivalent tool.
- Install 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).
- Tighten bolt to 39.2 to 49.0 Nm (29 to 36 ft. lbs.).
- Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 to 65 degrees.
- Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
For the following operations, perform steps in the reverse order of removal.