EM-204
[VK45DE]
TIMING CHAIN
Revision: 2006 January2006 M35/M45
Removal and InstallationNBS004P8
REMOVAL
1. Remove engine assembly from vehicle. Refer to EM-244, "ENGINE ASSEMBLY" .
2. Remove the following components and related parts:
Drive belt auto tensioner and idler pulley; Refer to EM-176, "Drive Belt Auto Tensioner and Idler Pulley"
.
Thermostat housing and hoses; Refer to CO-55, "THERMOSTAT AND WATER CONTROL VALVE" .
Ignition coil; Refer to EM-190, "IGNITION COIL" .
Rocker cover; Refer to EM-199, "ROCKER COVER" .
3. If necessary, remove intake valve timing control position sensor
(right and left bank) and camshaft position sensor (PHASE) from
intake valve timing control cover and front cover.
CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
4. If necessary, remove intake valve timing control solenoid valve from intake valve timing control cover.
CAUTION:
Handle components and parts 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.
1. Camshaft sprocket (EXH) 2. Camshaft sprocket (INT) 3. Camshaft sprocket (INT)
4. Camshaft sprocket (EXH) 5. Front cover 6.Intake valve timing control solenoid
valve (right bank)
7. O-ring 8. Seal ring 9.Intake valve timing control position
sensor (right bank)
10. O-ring 11.Intake valve timing control cover
(right bank)12.Intake valve timing control position
sensor (left bank)
13. O-ring 14.Intake valve timing control cover (left
bank)15. Seal ring
16.Intake valve timing control solenoid
valve (left bank)17. O-ring 18. Oil level gauge
19. Oil level gauge guide 20. O-ring 21. Crankshaft pulley bolt
22. Crankshaft pulley 23. Front oil seal 24. Chain tensioner cover
25. Camshaft position sensor (PHASE) 26. O-ring 27. Oil pump drive spacer
28. Oil pump assembly 29. Crankshaft sprocket 30. O-ring
31. O-ring 32.Timing chain tension guide
(right bank)33.Timing chain slack guide
(right bank)
34. Timing chain (right bank) 35. Timing chain (left bank) 36. Chain tensioner (left bank)
37. Chain tensioner (right bank) 38.Timing chain slack guide
(left bank)39.Timing chain tension guide
(left bank)
40. O-ring
PBIC0050E
TIMING CHAIN
EM-211
[VK45DE]
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Revision: 2006 January2006 M35/M45
7. Install oil pump drive spacer as follows:
a. Insert oil pump drive spacer according to the directions of crank-
shaft key and the two flat surfaces of oil pump inner rotor.
If the positional relationship does not allow the insertion,
rotate oil pump inner rotor with a finger to allow spacer.
b. After confirming that the position of each part is in correct condi-
tion to allow for spacer, force fit spacer by lightly tapping with
plastic hammer until it contacts and does not go further.
8. Install front oil seal on front cover.
Apply new engine oil to both oil seal lip and dust seal lip.
Install it so that each seal lip is oriented as shown in the fig-
ure.
CAUTION:
Be careful not to scratch or make burrs on circumference
of oil seal.
Using front oil seal drift (commercial service tool), press fit
until the height of front oil seal is level with the mounting sur-
face.
Make sure the garter spring is in position and seal lips not
inverted.
9. Install chain tensioner cover to front cover.
Apply a continuous bead of liquid gasket with tube presser
[SST: WS39930000 ( — )] to front cover as shown in the
figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
10. Install front cover as follows:
PBIC0058E
SEM715A
Front oil seal drift
Outer diameter : 56 mm (2.20 in)
Inner diameter : 49 mm (1.93 in)
PBIC0059E
SBIA0372E
EM-214
[VK45DE]
TIMING CHAIN
Revision: 2006 January2006 M35/M45
f. Further tighten by 90 degrees. (Angle tightening)
Check the tightening angle by referencing to the notches. The
angle between two notches is 90 degrees.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
16. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
PBIC2346E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
CAMSHAFT
EM-221
[VK45DE]
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Revision: 2006 January2006 M35/M45
4. Tighten camshaft bracket bolts in the following steps, in numeri-
cal order as shown in the figure.
a. Tighten No. 9 to 12 in numerical order as shown.
b. Tighten No. 1 to 8 in numerical order as shown.
c. Tighten No. 13 to 14 in numerical order as shown. (Left bank
only)
d. Tighten all bolts in numerical order as shown.
e. Tighten No. 1 to 12 in numerical order as shown.
f. Tighten No. 13 to 14 in numerical order as shown. (Left bank
only)
CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the parts listed below.
Mating surface of rocker cover
Mating surface of front cover
5. Install camshaft sprockets.
Install by checking with identification mark on surface.
Instal camshaft sprocket (EXH) by selectively using the
groove of dowel pin according to the bank. (Common part
used for both banks.)
Lock the hexagonal part of camshaft in the same way as for
removal, and tighten mounting bolts.
6. Check and adjust the valve clearance. Refer to EM-222, "
Valve Clearance" .
7. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
Perform this inspection only when DTC P0011 and/or P0021 are detected in self-diagnostic results
of CONSULT-II and it is directed according to inspection procedure of EC section. Refer to EC-850,
"SELF-DIAG RESULTS MODE" .
Check when the engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer toLU-26, "
ENGINE OIL" .
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer toEC-809, "
FUEL PRESSURE RELEASE" .
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-203, "
TIMING CHAIN" . : 1.96 Nꞏm (0.2 kg-m, 1 ft-lb)
: 1.96 Nꞏm (0.2 kg-m, 1 ft-lb)
: 1.96 Nꞏm (0.2 kg-m, 1 ft-lb)
: 5.88 Nꞏm (0.6 kg-m, 4 ft-lb)
: 10.41 Nꞏm (1.1 kg-m, 8 ft-lb)
: 31.35 Nꞏm (3.2 kg-m, 23 ft-lb)
PBIC0031E
PBIC2345E
EM-222
[VK45DE]
CAMSHAFT
Revision: 2006 January2006 M35/M45
4. Crank the engine, and then make sure that engine oil comes out
from intake valve timing control cover oil hole. End crank after
checking.
WA R N I N G :
Be careful not to touch rotating parts (drive belt, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
Engine oil may squirt from intake valve timing control sole-
noid valve installation hole during cranking. Use a shop
cloth to prevent the engine components and the vehicle. Do
not allow engine oil to get on rubber components such as
drive belt or engine mount insulators. Immediately wipe off
any splashed engine oil.
Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from intake valve timing control cover oil hole. Refer to LU-24, "
LUBRICATION SYSTEM" .
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
Clean oil groove if necessary. Refer to LU-24, "LUBRICATION SYSTEM" .
6. After inspection, install removed parts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Valve ClearanceNBS004PB
INSPECTION
In cases of removing/installing or replacing camshaft and valve-related parts, or of unusual engine conditions
due to changes in valve clearance (found malfunctions during starting, idling or causing noise), perform
inspection as follows:
1. Remove rocker covers (right and left bank). Refer to EM-199, "
ROCKER COVER" .
PBIC2848E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
OIL SEAL
EM-231
[VK45DE]
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Revision: 2006 January2006 M35/M45
Install front oil seal so that each seal lip is oriented as shown
in the figure.
Using front oil seal drift, press fit until the height of front oil
seal is level with the mounting surface.
Make sure the garter spring is in position and seal lips not
inverted.
CAUTION:
Be careful not to damage front cover and oil pump drive
spacer.
Press fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal.
Removal and Installation of Rear Oil SealNBS004PE
REMOVAL
1. Remove transmission assembly. Refer to AT- 2 7 1 , "TRANSMISSION ASSEMBLY" .
a. Remove drive plate. Refer to EM-249, "
CYLINDER BLOCK" .
b. Remove rear plate. Refer to EM-249, "
CYLINDER BLOCK" .
2. Remove rear oil seal using suitable tool.
CAUTION:
Be careful not to damage crankshaft and oil seal retainer
surface.
INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new rear oil seal.
2. Install rear oil seal.
Install rear oil seal so that each seal lip is oriented as shown
in the figure.
SEM715A
Front oil seal drift
Outer diameter : 56 mm (2.20 in)
Inner diameter : 49 mm (1.93 in)
SBIA0359E
SBIA0360E
SEM715A
EM-232
[VK45DE]
OIL SEAL
Revision: 2006 January2006 M35/M45
Using rear oil seal drift (commercial service tool), press fit
until the height of front oil seal is level with the mounting sur-
face.
Make sure the garter spring is in position and seal lips not
inverted.
CAUTION:
Be careful not to damage crankshaft and rear oil seal
retainer.
Press fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal.Rear oil seal drift
Outer diameter : 102 mm (4.02 in)
Inner diameter : 86 mm (3.39 in)
SBIA0360E
EM-234
[VK45DE]
CYLINDER HEAD
Revision: 2006 January2006 M35/M45
If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
–If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the
piston rings and replace if necessary.
–If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
8. After inspection is completed, install removed parts in the reverse order of removal.
9. Start engine, and make sure that engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-811, "
TROUBLE DIAGNOSIS" .
ComponentsNBS004PG
Removal and InstallationNBS004PH
REMOVAL
1. Remove engine assembly from vehicle. Refer to EM-244, "ENGINE ASSEMBLY" .
2. Remove exhaust manifold. Refer to EM-183, "
EXHAUST MANIFOLD AND THREE WAY CATALYST" .
3. Remove camshaft. Refer to EM-215, "
CAMSHAFT" .
1. Engine coolant temperature sensor 2. Washer 3. Cylinder head gasket (left bank)
4. Harness bracket 5. Cylinder head (right bank) 6. Cylinder head bolt
7. Cylinder head gasket (right bank) 8. Cylinder head bolt 9. Cylinder head (left bank)
PBIC2756E