Removal & Installation
- 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.
NOTEThe 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 valve covers as follows:
- Remove the engine cover.
- Remove side engine covers.
If removing right hand valve cover, remove the following:
Front cowl panel
- 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.
Check that intake and exhaust camshaft lobes on No. 1 cylinder (right bank of engine) are located as illustrated. If not, turn the crankshaft one revolution (360 degrees) and align as illustrated.
Lock the ring gear using tool J-44716 attached to the starter bolt hole.
CAUTIONDo 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:
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.
CAUTIONAfter 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.
NOTEThe intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. Handle the intake sprockets as an assembly.
CAUTIONThe 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.
NOTEDo 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:
CAUTIONDo 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.
- Disconnect the inlet coolant hose.
- Remove the inlet coolant housing, gasket and thermostat.
- Remove the O-rings on the cylinder head and cylinder block.
- Loosen the No. 1 camshaft bracket bolts in several steps in the sequence illustrated and remove No. 1 camshaft brackets.
- Remove the camshaft chain tensioners, for secondary timing chains.
- If necessary, remove the water pump.
- Use a scraper to remove all of the old sealant from the front and rear timing chain case mating surfaces and the bolt holes, bolts, camshaft No. 1 bracket and water pump cover. Being careful not to damage the mating surfaces.
Remove the front oil seal from the front timing chain case using a suitable tool.
- Check for cracks and any excessive wear at the roller links of the timing chain. Replace the timing chain as necessary.