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b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of bank 1) are located as shown in the figure.
If not, turn crankshaft one revolution (360 degrees) and align
as shown in the figure.
10. Remove crankshaft pulley as follows:
a. Fix crankshaft with the pulley holder (commercial service tool)
(A).
b. Loosen crankshaft pulley bolt and locate bolt seating surface at
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a
supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull
crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery,
as this will damage internal damper.
11. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
JPBIA0044ZZ
1 : Crankshaft pulley
PBIC3961E
SEM915E
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b. Insert a suitable tool (A) into the notch at the top of front timing
chain case as shown in the figure.
c. Pry off case by moving the tool as shown in the figure.
Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid
gasket for removal.
CAUTION:
Never use screwdrivers or something similar.
After removal, handle front timing chain case carefully so
it does not tilt, cant, or warp under a load.
12. Remove water pump cover from front timing chain case.
Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
13. Remove front oil seal from front timing chain case using a suit-
able tool.
Use a screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
14. Remove O-ring (1) from rear timing chain case.
15. Remove timing chain tensioner (primary) as follows:
a. Remove lower mounting bolt (1).
b. Loosen upper mounting bolt (2) slowly, and then turn timing
chain tensioner (primary) (3) on the mounting bolt so that
plunger (4) is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
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EMQ0032D
A: Bank 1
B: Bank 2
JPBIA1111ZZ
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16. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
17. Remove timing chain (primary) and crankshaft sprocket.
CAUTION:
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves
will strike the piston heads.
18. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2
(C) timing chain tensioners (secondary) (1).
NOTE:
Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
For removal of timing chain tensioner (secondary), refer to
EM-84, "
Exploded View". [Removing camshaft bracket (No. 1)
is required.]
b. Remove camshaft sprockets (INT and EXH) mounting bolts.
Secure the hexagonal portion of camshaft using a wrench to
loosen mounting bolts.
CAUTION:
Never loosen mounting bolts with securing anything
other than the camshaft hexagonal portion or with ten-
sioning the timing chain.
c. Remove timing chain (secondary) together with camshaft sprockets.
Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
PBIC2266E
JPBIA1727ZZ
KBIA1698J
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Insert 0.5 mm (0.020 in) thick metal or resin plate between tim-
ing chain and timing chain tensioner plunger (guide) (F).
Remove timing chain (secondary) (1) together with camshaft
sprockets with timing chain loose from guide groove.
CAUTION:
Be careful of plunger coming-off when removing timing chain (secondary). This is because
plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of
fixed stopper pin.
NOTE:
Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing
chain (secondary).
Figure is shown as an example of bank 1.
When handling camshaft sprocket (INT), be careful of the following caution:
CAUTION:
Handle carefully to avoid any shock to camshaft sprocket.
Never disassemble. [Never loosen bolts (A) as shown in
the figure].
19. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
Remove timing chain tensioners (secondary) with a stopper pin attached.
20. Use a scraper to remove all traces of old liquid gasket from front
timing chain case, and opposite mating surfaces.
Remove old liquid gasket from bolt hole (B) and thread.
A: Bank 1
B : Timing chain tensioner (Body)
C: View C
D : Stopper pin
E: Plate
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PBIC2980E
SEM737G
A : Remove sticking old liquid gasket
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TIMING CHAIN
21. Use a scraper to remove all traces of old liquid gasket from
water pump cover.
INSTALLATION
NOTE:
The below figure shows the relationship between the mating mark on each timing chain and that on the corre-
sponding sprocket, with the components installed.
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-84,
"Exploded View".
Install timing chain tensioners (secondary) with a stopper pin attached and new O-ring.
SEM926E
1. Internal chain guide 2. Camshaft sprocket (INT) 3. Timing chain (secondary)
4. Camshaft sprocket (EXH) 5. Timing chain tensioner (primary) 6. Slack guide
7. Timing chain (primary) 8. Crankshaft sprocket 9. Water pump
10. Tension guide 11. Timing chain tensioner (secondary) 12. Crankshaft key
A. Mating mark B. Mating mark (pink link) C. Mating mark (punched)
D. Mating mark (orange) E. Mating mark (notched)
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2. Check that dowel pin hole, dowel pin and crankshaft key are
located as shown in the figure. (No. 1 cylinder at compression
TDC)
NOTE:
Though camshaft does not stop at the position as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Never misidentify (ignore big
dia. side).
3. Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows:
CAUTION:
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin (A).
b. Install timing chain (secondary) (1) and camshaft sprockets (INT
and EXH).
NOTE:
Figure shows bank 1 (rear view).
Align the mating marks on timing chain (secondary) (orange
link) with the ones on camshaft sprockets (INT and EXH)
(punched), and install them.
NOTE:
Mating marks for camshaft sprocket (INT) are on the back
side of camshaft sprocket (secondary).
There are two types of mating mark, circle and oval types.
They should be used for the bank 1 and bank 2, respectively. Camshaft dowel pin hole (intake side)
: At cylinder head upper face side in each bank
Camshaft dowel pin (exhaust side)
: At cylinder head upper face side in each bank
Crankshaft key
: At cylinder head side of bank 1
KBIA1073E
JPBIA0095ZZ
A : Camshaft sprocket (INT) back face
B : Orange link
C : Mating mark (Circle)
D : Camshaft sprocket (EXH) back face
E : Mating mark (2 circle on front face)
F : Dowel pin groove
G : Mating mark (2 ovals on front face)
H : Mating mark (Oval)
I : Dowel pin hole
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Align dowel pin and pin hole on camshafts with the groove and dowel pin on sprockets, and install them.
On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin on
the back side of camshaft sprocket, and install them.
On the exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket, and
install them.
In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine
adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is
enough to prevent the dislocation of dowel pins.
It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching eas-
ier, make a mating mark on the top of sprocket teeth and its
extended line in advance with paint.
c. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts.
Secure camshaft using wrench at the hexagonal portion to
tighten mounting bolts.
d. Pull stopper pins (B) out from timing chain tensioners (second-
ary) (1).
4. Install tension guide.
5. Install timing chain (primary) as follows:Bank 1 : Use circle type.
Bank 2 : Use oval type.
PBIC0891E
KBIA1698J
A: Bank 1
C: Bank 2
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a. Install crankshaft sprocket (1).
Check the mating marks on crankshaft sprocket face the front
of the engine.
b. Install timing chain (primary).
Install timing chain (primary) so the mating mark (punched) on
camshaft sprocket (INT) is aligned with the pink link on timing
chain, while the mating mark (notched) on crankshaft sprocket
is aligned with the orange one on timing chain, as shown in the
figure.
When it is difficult to align mating marks of timing chain (pri-
mary) with each sprocket, gradually turn camshaft using
wrench on the hexagonal portion to align it with the mating
marks.
During alignment, be careful to prevent dislocation of mating
mark alignments of timing chains (secondary).
6. Install internal chain guide, slack guide and timing chain ten-
sioner (primary).
A : Crankshaft side
B : Engine front side
C : Mating mark (Front side)
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PBIC3494E
PBIC2109E