Removal & Installation
- Install the camshaft chain tensioners, for secondary timing chain Tighten the bolts to 75 inch lbs. (9 Nm).
- Before installing the No. 1 camshaft bracket, apply sealant to mating surface and wipe off any excess sealant before installation.
- Tighten the No. 1 camshaft bracket in three steps, in the order illustrated as follows:
Step 1: 17 inch lbs. (2 Nm).
- Step 2: 52 inch lbs. (6 Nm).
- Step 3: 92 inch lbs. (10 Nm).
- Install the thermostat, gasket and coolant inlet housing. Tighten the bolts to 87 inch lbs. (10 Nm).
- Install rear timing chain case as follows:
Apply silicone sealant to rear timing chain case as illustrated, clean off the protruding sealant prior to installation.
- Align the rear timing chain case with the dowel pins on the cylinder block and install the case. Make sure the O-rings stay in place during installation.
- Tighten the rear timing chain case bolts in the order illustrated.
- Install the 0.79 inch (20 mm) bolts in locations 1, 2, 3, 6, 7, 8, 9 and 10. Tighten to 9 ft. lbs. (13 Nm). Install the 0.63 inch (16 mm) bolts in locations 4, 5, 11 through 26 and tighten to 9 ft. lbs. (13 Nm).
- After all bolts are initially tightened, retighten them to the specification in the order illustrated.
After installing rear timing chain case, check surface height difference between the rear timing chain case to cylinder block. The measurement should be 0.0094-0.0055 inch (0.24-0.14 mm). If not within specification, repeat the cover installation procedure.
- Install the timing chain tension guide. Tighten the bolts to 9 ft. lbs. (13 Nm).
- 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 illustrated. The camshaft dowel pin hole (intake side): at cylinder head upper face side in each bank. The camshaft dowel pin (exhaust side): at cylinder head upper face side in each bank. The crankshaft key: at cylinder head side of right hand bank.
CAUTIONThe hole on small diameter side must be used for the intake camshaft sprocket dowel pin. Do not misidentify (ignore the big diameter side).
Install the secondary timing chains and camshaft sprockets as follows:
CAUTIONMatch marks between the timing chain and sprockets can slip easily. Check all match mark positions repeatedly during the installation process. Push the sleeve of the secondary chain tensioner and keep it pressed in with a stopper pin.
Align the match marks on the secondary timing chain (gold link) with the ones on the intake and exhaust sprockets (stamped), and install them.
NOTEMatch marks for the intake sprocket are on the back side of the secondary sprocket. There are two types of match marks, round and oval types. They should be used for the right hand and left hand banks, respectively. The right hand banks use round type and the left hand bank use oval type.
- 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.
- Tighten the camshaft sprocket bolts by hand to prevent the dislocation of the dowel pins.
- Align the match marks on the secondary timing chain (gold link) with the ones on the intake and exhaust sprockets (stamped), and install them.
Tighten the timing chain tension guide bolts to 16 ft. lbs. (21 Nm).
NOTEIt 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 sprocket teeth in advance with paint.
- After confirming the mating marks are aligned, tighten the camshaft sprocket bolts to 76 ft. lbs. (102 Nm).
- Remove the stopper pins out from the timing chain tensioners, on secondary timing chains.
Install the crankshaft sprocket on the crankshaft. Make sure the mating marks on the crankshaft sprocket face the front of the engine.
Install the primary timing chain as follows:
Install the primary timing chain so the mating mark (punched) on the camshaft sprocket is aligned with the copper link on the timing chain, while the mating mark (notched) on the crankshaft sprocket is aligned with the gold link on the timing chain, as illustrated.
NOTEWhen 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 primary timing chain so the mating mark (punched) on the camshaft sprocket is aligned with the copper link on the timing chain, while the mating mark (notched) on the crankshaft sprocket is aligned with the gold link on the timing chain, as illustrated.
- Install the internal chain guide. Tighten the bolts to 72 inch lbs. (8 Nm).
Install the slack guide and tighten to 12 ft. lbs. (15 Nm). Do not over-tighten the slack guide installation bolt. It is normal for a gap to exist under the bolt seats when the bolt is tightened to specification.
Install the timing chain tensioner for the slack guide as follows:
- 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.
- Tighten the bolts to 72 inch lbs. (8 Nm).
- After installation, pull out the stopper pin by pressing the slack guide.
- Confirm that the match 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 using a suitable tool. Apply clean engine oil to the oil seal edges.- Install the seal so that each seal lip is oriented as illustrated. Using a suitable drift, press-fit oil seal until it becomes flush with timing chain case end face. Make sure the garter spring in the oil seal is in position and seal lip is not inverted.
- Install the front timing cover case.
- Install IVT control valve covers as follows:
- 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 IVT control covers.
- Tighten the intake valve timing control cover bolts in the order illustrated to 100 inch lbs. (11 Nm).
- Apply a 0.091-0.130 inch (2.3-3.3mm) bead of liquid gasket to the water pump cover and the chain tensioner cover and install covers. Tighten the bolts on the pump and cover to 97 inch lbs. (11 Nm).
Install crankshaft pulley lubricate the pulley bolt with clean engine oil and tighten the bolt in two steps:
- Step 1: 32 ft. lbs. (44 Nm).
- Step 2: 60-65 degrees clockwise.
- Rotate crankshaft pulley in a clockwise direction as viewed from front of the engine to confirm it turns smoothly.
- Install the right hand engine mount.
- Install the valve covers in the reverse order of removal, make sure to perform the following:
- Apply sealant to the areas on the front corners.
Tighten the valve cover bolts in two steps in the sequence illustrated:
- Step 1: 17 inch lbs. (1.96 Nm).
- Step 2: 74 inch lbs. (8 Nm).
Install the remaining components is in reverse order of removal.
NOTEIf hydraulic pressure inside chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. This is normal. Noise will stop after hydraulic pressure rises.
- Before servicing the vehicle, refer to the Precautions section.
- Remove the engine from the vehicle.
- Remove the idler pulley and bracket.
- Remove the upper and lower oil pans.
- Remove the alternator.
- Remove the timing chain tensioner cover.
- Remove both the IVT control covers, remove the bolts in the sequence illustrated.
The shaft in the cover is inserted into the center hole of the intake camshaft sprocket. Remove the cover by pulling straight out until the cover disengages from the camshaft sprocket.
- Remove the starter.
- Remove the intake manifold collector.
Remove the rocker covers as follows:
- Remove the engine cover.
- Remove side engine covers.
If removing right hand rocker cover, remove the following:
- Front cowl panel
- Windshield wiper arms and motor assembly
- Intake manifold collector.
- If removing left hand rocker cover, disconnect the Air Fuel Ratio (AFR) sensor.
- Remove the ignition coils.
- Position engine harness aside.
- Disconnect Positive Crankcase Ventilation (PCV) hose.
- Remove the dipstick.
- Remove the rocker cover bolts in the sequence illustrated.
- Remove the spark plugs.
- Disconnect and remove the IVT control solenoid valves and discard the gaskets
Place the engine at Top Dead center (TDC) of No. 1 cylinder as follows:
Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with the timing indicator.
- Lock the ring gear using tool J-44716 attached to the starter bolt hole.
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the tool.
Remove the crankshaft pulley as follows:
- Loosen crankshaft pulley bolt using tool KV10109300 and locate bolt seating surface at 0.39 inch (10 mm) from its original position.
- Position a pulley puller at recess hole of crankshaft pulley to remove crankshaft pulley.
Do not use a puller claw on crankshaft pulley.
- Remove the front timing chain case after loosening the front timing chain case bolts in the order illustrated.
- Remove the internal chain guide.
Remove the timing chain tensioner and slack guide as follows:
- Put matchmarks on the timing chain and sprockets to indicate the correct position of the components to aid during installation.
- Pull the lever down and release the plunger stopper tab. The plunger stopper tab can be pushed up to release (coaxial structure with lever).
- Insert a 0.098 inch (2.5mm) Allen wrench into the tensioner body hole to hold the lever, and keep the tab released.
- Insert the plunger into tensioner body by pressing the slack side chain guide.
- Keep the slack side chain guide pressed and hold it by pushing a stopper pin such as a 0.098 inch (2.5mm) Allen wrench through the lever hole and body hole.
- Remove the timing chain tensioner bolts and the timing chain tensioner.
- Remove the slack guide bolt and the guide.
- Remove primary timing chain and crankshaft sprocket.
After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
- Attach a suitable stopper pin such as a 0.098 inch (2.5mm) Allen wrench to the right and left camshaft chain tensioners, for secondary timing chains.
- Remove the intake and exhaust camshaft sprocket bolts. Put matchmarks on the timing chain and camshaft sprockets to aid alignment during installation.
- Use a wrench on the hexagonal portion of the camshaft and loosen the bolts as illustrated.
Remove the secondary timing chains with camshaft sprockets as follows:
- Rotate camshaft slightly, and slacken timing chain of timing chain tensioner side.
- Insert a 0.020 inch (0.5 mm) metal or resin plate into the guide between timing chain and chain tensioner plunger.
- Remove the camshaft sprocket and secondary timing chain with the timing chain removed from guide groove.
The intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. Handle the intake sprockets as an assembly.
The chain tensioner plunger can move while stopper pin is inserted in tensioner. The plunger can come out of tensioner when timing chain is removed. Use caution during removal.
Do not disassemble the intake sprockets (never loosen bolts A and B shown in the accompanying illustration).
- Remove the timing chain tension guide.
- Remove the rear timing chain case as follows:
Do not remove the plate metal cover for the oil passage. After removing the chain case, do not apply any load to the case that might bend it.
- Loosen and remove the rear timing chain case bolts in the order illustrated.
- Cut the sealant using tool J-37228 and remove the rear timing chain case.