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16. Remove primary timing chain with fuel pump sprocket and
crankshaft sprocket.
17. Remove chain guide and tension guides.
18. Remove fuel pump. Refer toEM-49, "
FUEL PUMP".
19. Remove vacuum pump. Refer toEM-42, "
VACUUM PUMP".
MBIA0074E
MBIA0079E
JEM885G
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PRIMARY TIMING CHAIN
20. Remove rear chain case.
lLoosen fixing bolts in the reverse order of that shown in the
figure and remove them.
lU s e t h e s e a l c u t t e r [ S S T: K V 1 0 1111 0 0 ] f o r r e m o v a l .
21. Remove balancer unit (4WD models).
lLoosen mounting bolts in the reverse order as shown in the
figure.
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
SBIA0211E
: Engine front
PBIC4049E
SEM984C
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Balancer Unit Mounting Bolt Outer Diameter (4WD Models)
lMeasure the outer diameters (“d1”,“d2”)attwopositionsas
showninthefigure.
lIf reduction appears in “A” range, regard it as “d2”.
lIf it exceeds the limit (large difference in dimensions), replace it
with a new one.
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
CAUTION:
Before starting work, make sure that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
order as shown in the figure (4WD models).
CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer toEM-85, "
Balancer Unit Mounting
Bolt Outer Diameter (4WD Models)".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
b. Tighten all bolts.Limit (“d
1”-“d2
”): 0.15 mm (0.0059 in)
PBIC1137E
1. Chain tensioner 2. Slack guide 3. Fuel pump sprocket
4. Chain guide 5. Primary timing chain 6. Vacuum pump sprocket
7. Slack guide 8. Chain tensioner 9. Crankshaft sprocket
10. Key 11. Tension guide 12. Tension guide
13. Tension guide 14. Camshaft sprocket 15. Secondary timing chain
A. Alignment mark (silver link) B. Alignment mark (punched mark) C. Alignment mark (cut-out area)
D. Alignment mark (yellow link)
: Engine front
PBIC3473E
PBIC4049E
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PRIMARY TIMING CHAIN
c. Turn all bolts 65 degrees clockwise (angle tightening).
d. Completely loosen.
CAUTION:
In this step, loosen bolts in the reverse order as shown in
the figure.
e. Tighten all bolts.
f. Turn them another 65 degrees clockwise (angle tightening).
CAUTION:
Check tightening angle with an angle wrench [SST] (A) or a protractor. Do not make judgment by
visual check alone.
2. Install rear chain case.
a. Apply a continuous bead of liquid gasket with the tube presser
[SST: WS39930000] on locations shown in the figure.
Use Genuine Liquid Gasket or equivalent.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
b. Install four O-rings to the grooves of the cylinder block and fuel
pump bracket.
c. Install rear chain case.
lWhen installing, align the dowel pin with the pin hole.: 29.4 N·m (3.0 kg-m, 22 ft-lb)
1 : Balancer unit
A : KV10112100
: 0 N·m (0 kg-m, 0 ft-lb)
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC3474E
PBIC1255E
JEM141G
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d. Tighten bolts in numerical order shown in the figure.
lInstall the following four types of bolts, referring to the figure.
lThe shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.
3. Install vacuum pump. Refer toEM-42, "
VACUUM PUMP".
4. Install fuel pump. Refer toEM-49, "
FUEL PUMP".
lBefore installing, make sure that spacer and the hole 6 mm
(0.24 in) in diameter on coupling are aligned.
5. Install chain guide and tension guides.
6. Install crankshaft sprocket, aligning it with crankshaft key on the
far side.
7. Install primary timing chain with fuel pump sprocket.
lWhen installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain.
lInstall fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.
8. Install timing chain onto power steering oil pump sprocket and
through chain guide.
9. Use the positioning stopper pin [SST] to hold the fuel pump
sprocket and install the bolt.
lUsing the TORX wrench [SST], turn the fuel pump shaft little
by little to adjust the position of the fuel pump sprocket. Insert
positioning stopper pin into the hole 6 mm (0.24 in) in diame-
ter on fuel pump sprocket so that the stopper pin goes
through the fuel pump body. While the stopper pin is in place,
install the bolt.16 mm (0.63 in) : Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
20mm(0.79in) :BoltNo.3,4,6,9,10,11,13,14
25 mm (0.98 in) : Bolt No. 12, 15
35 mm (1.38 in) : Bolt No. 5, 7, 8
SBIA0211E
JEM885G
MBIA0079E
MBIA0049E
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PRIMARY TIMING CHAIN
10. Install timing chain slack guide.
11. Install chain tensioner.
lPush the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install chain
tensioner.
lAfter installation, pull out the push pin holding the plunger.
CAUTION:
Make sure again that the alignment marks on sprockets and
the colored alignment marks on timing chain are aligned.
12. Install front oil seal (1) to oil pump housing (2).
lUsing the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION:
Do not touch lips of oil seal. Make sure seal surfaces are
free of foreign materials.
13. Install vacuum pump cover to oil pump housing.
lApply a continuous bead of liquid gasket with the tube presser
[SST: WS39930000] as shown in the figure.
Use Genuine Liquid Gasket or equivalent.
lApply liquid gasket on oil pump-side surface.
14. Install crankshaft gear.
lInstall crankshaft gear with the following procedure (4WD models).
PBIC2404E
JEM134G
PBIC3448E
JEM143G
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–Align crankshaft gear (1) mating mark and idler sub gear (3)
mating mark (C).
–Remove internal mechanism securing bolt and plate (Service
part: 13012 EB30A and 13013 EB30A) (A).
–If new balancer unit (2) is used, align matching marks (B) of
each gear as shown in the figure.
–Remove securing-bolt-and-plate (A) and securing pin (C) after
installing crankshaft gear (1).
15. Install oil pump housing.
a. Apply a continuous bead of liquid gasket with the tube presser
[SST: WS39930000] as shown in the figure.
A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump hous-
ing.
2 : Idler main gear
4 : Balancer drive shaft front end
5 : Idler gear mounting bolt (do not loosen)
B : Snap ring plier
PBIC3471E
PBIC3475E
JEM144G
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PRIMARY TIMING CHAIN
b. Install O-ring into the groove of rear chain case.
c. Install oil pump housing.
lWhen installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
lWhen installing, align the dowel pin with the pin hole.
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
16. Check gaps on upper oil pan mounting surface.
lUsing straightedge and feeler gauge, measure gaps between
the locations of the following parts:
lIf the measured value is out of the standard, install again.
17. Install crankshaft pulley.
CAUTION:
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
c. Hold crankshaft pulley with the pulley holder [SST].
d. Tighten crankshaft pulley fixing bolt.
e. Completely loosen.
f. Tighten crankshaft pulley bolt.
g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt.
PBIC3470E
Oil pump housing and rear chain case:
Standard : – 0.09 to 0.09 mm (– 0.0035 to 0.0035 in)
Rear chain case and cylinder block:
Standard : – 0.19 to 0.07 mm (– 0.0075 to 0.0028 in)
JEM146G
: 75.0 N·m (7.7 kg-m, 55 ft-lb)
:0N·m(0kg-m,0ft-lb)
: 75.0 N·m (7.7 kg-m, 55 ft-lb)
PBIC3469E