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TIMING CHAINEM-63
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b. Loosen mounting bolts in the reverse order as shown in the fig-
ure.
CAUTION:
Exercise care not to damage mating surfaces.
Shaft is internally jointed with camshaft sprocket center
hole. When removing, keep it horizontal until it is com-
pletely disconnected.
15. Remove intake valve timing control solenoid valve (bank 1 and bank 2), if necessary. CAUTION:
Valve timing control solenoid valve is no t reusable. Never remove it unless required.
16. Remove O-rings (1) from front cover.
17. Remove rocker cover. Refer to EM-33, "
Exploded View".
18. Obtain No. 1 cylinder at TDC of its compression stroke. Refer to EM-12, "
Inspection".
19. Remove crankshaft pulley. Refer to EM-96, "
FRONT OIL SEAL : Removal and Installation".
20. Remove water pump pulley. Refer to CO-18, "
Exploded View".
21. Remove oil pan (lower) and oil strainer. Refer to EM-54, "
Exploded View".
22. Remove oil pan (upper). Refer to EM-57, "
Exploded View".
23. Remove front cover as per the following:
a. Loosen mounting bolts (A), and then remove camshaft bracket (1).
b. Loosen mounting bolts in reverse order as shown in the figure.
c. Insert a suitable tool into the notch at front cover. Pry off case by moving a suitable tool.
CAUTION:
Exercise care not to damage mating surfaces.
After removal, handle front cover carefully so it does not
tilt, cant, or warp under a load.
A: Bank 2
B: Bank 1
C : Dowel pin hole
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EM-64
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TIMING CHAIN
24. Remove oil pump and oil pump drive spacer.
25. Remove front oil seal from front cover using suitable tool. Use screwdriver for removal.
CAUTION:
Be careful not to damage front cover.
26. Remove O-rings (1), (2), (3) from cylinder heads and cylinder block.
27. Remove oil filter (for valve timing control solenoid valve), if necessary.
28. Remove timing chain tensioner cover from front cover, if necessary. Use seal cutter [SST: KV10111100 (J-37228)] to cut liquid gasket for removal.
29. Remove timing chain tensioner (bank 1) as per the following: NOTE:
To remove timing chain and related parts, start with those on bank 1. The procedure for removing parts on
bank 2 is omitted because it is the same as that for bank 1.
a. Push both sides of spring (A) against spring tension, and then press in plunger with a slack guide (2).
b. Insert a stopper pin (A) into the body hole, and then fix it with the
plunger pushed in.
30. Remove high pressure fuel pump camshaft.
31. Remove tension guide and slack guide.
32. Remove exhaust camshaft sprocket as per the following: Secure the hexagonal portion of exhaust camshaf t using a wrench to loosen mounting bolt.
33. Remove timing chain and crankshaft sprocket. CAUTION:
After removing timing chain, never turn cranksh aft and camshaft separately, or valves will strike
the piston head.
34. Remove intake camshaft sprocket as per the following:
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1 : Timing chain tensioner (bank 1)
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TIMING CHAINEM-65
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Secure the hexagonal portion (located in between journal No.1
and journal No. 2) of drive shaft (A) using a wrench (B) to
loosen mounting bolt.
NOTE:
The figure shows an example of bank 2.
CAUTION:
Never loosen the mounting bolt by securing anyt hing other than the camshaft (drive shaft) hexago-
nal portion or with tensioning the timing chain.
When holding the hexagonal part of camshaft (drive shaft) with a wrench, be careful not to allow the
wrench to cause interference with other parts.
Never disassemble camshaft sprocket. [Never loosen bolts (B) as shown in the figure.]
35. Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces. Remove old liquid gasket from bolt hole and thread.
INSTALLATION
: Engine front
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A: Intake
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A : Remove old liquid gasket that is stuck
B : Bolt hole
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EM-66
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TIMING CHAIN
NOTE:
The above figure shows the relationship between the matching mark on each timing chain and that on the
corresponding sprocket, with the components installed.
Parts with an identification mark (R or L) should be installed on the corresponding bank according to the
mark.
- Intake camshaft sprocket, exhaust camshaft sprocket
- Tension guide
- Slack guide
To install timing chain and related parts, start with those on bank 2. The procedure for installing parts on
bank 1 is omitted because it is the same as that for installation on bank 2.
1. High pressure fuel pump camshaft 2. Intake camshaft sprocket (bank 2) 3. Exhaust camshaft sprocket (bank 2)
4. Timing chain (bank 2) 5. Slack guide (bank 2) 6. Chain oil jet (bank 2)
7. Timing chain tensioner (bank 2) 8. Crankshaft sprocket (bank 2 side) 9. Crankshaft sprocket (bank 1 side)
10. Chain oil jet (bank 1) 11. Tension guide (bank 1) 12. Timing chain (bank 1)
13. Exhaust camshaft sprocket (bank 1) 14. Intake camshaft sprocket (bank 1) 15. Timing chain tensioner (bank 1)
16. Slack guide (bank 1) 17. Tension guide (bank 2) 18. Dowel pin
A: Matching mark (copper link) B: Matching mark (punched) C: Matching mark (outer groove)
D: Matching mark (white link) E. Matching mark (notched) F. Matching mark (yellow link)
G. Crankshaft key
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TIMING CHAINEM-67
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1. Check that crankshaft key (1) and dowel pin (A) of each cam-
shaft are located as shown in the figure.
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.
2. Install camshaft sprockets (INT and EXH). Install onto correct side by checking with identification mark(A) on surface.
Exhaust side: Secure the hexagonal portion of exhaust camshaft using a wrench to tighten mounting bolt. Refer toEM-74, "
Exploded View".
Intake side:
Secure the hexagonal portion (located in between journal No.1and journal No. 2) of drive shaft (A) using a wrench (B) to
tighten mounting bolt. Refer to EM-74, "
Exploded View".
NOTE:
The figure shows an example of bank 2.
3. Install high pressure fuel pump camshaft.
4. Install timing chains as per the following:
a. Install crankshaft sprockets for both banks. Install each crankshaft sprocket so that its flange side (thelarger diameter side without teeth) (A) faces in the direction
shown in the figure.
NOTE:
The same parts are used but facing directions are different.Camshaft dowel pin
: At cylinder head upper face side in each bank
Crankshaft key : Straight up
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: Engine front
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1 : Crankshaft sprocket (bank 1 side)
2 : Crankshaft sprocket (bank 2 side)
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EM-68
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TIMING CHAIN
b. Install timing chains.
Bank 2 (F): Install timing chain so that the matching mark (punched) (B)and the matching mark (outer groove) (C) on camshaft
sprocket is aligned with the copper link (A) on timing chain,
while the matching mark (punched) (B) on crankshaft sprocket
is aligned with the yellow link (D) one on timing chain, as
shown in the figure.
Bank 1 (G): Install timing chain so that the matching mark (punched) (B)and the matching mark (outer groove) (C) on camshaft
sprocket is aligned with the copper link (A) on timing chain,
while the matching mark (notched) (E) on crankshaft sprocket
is aligned with the yellow link (D) one on timing chain, as
shown in the figure.
5. Install slack guides and tension guides onto correct side by checking with identification mark (A) on surface.
CAUTION:
Never overtighten slack guide mounting bolt (2). It is nor-
mal for a gap (A) to exist und er the bolt seats when mount-
ing bolt are tightened to the specification.
6. Install timing chain tensioner as per the following:
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1 : Slack guide (bank 2)
2 : Tension guide (bank 2)
3 : Slack guide (bank 1)
4 : Tension guide (bank 1)
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1 : Slack guide
3 : Cylinder block
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a. Fix the plunger at the most compressed position using a stopper
pin (A).
Remove any dirt and foreign materials completely from theback and the mounting surfaces of timing chain tensioner.
b. Pull out stopper pin after installing, and then release plunger.
7. Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.
8. Install oil pump and oil pump drive spacer. Refer to LU-13, "
Exploded View".
9. Install front oil seal on front cover. Refer to EM-96, "
FRONT OIL SEAL : Removal and Installation".
10. Install timing chain tensioner cover (2) to front cover (1).
Apply a continuous bead of liquid gasket with tube presser(commercial service tool) to front cover as shown in the figure.
Use Genuine RTV silicone seal ant or equivalent. Refer to
GI-22, "
Recommended Chemical Products and Sealants".
11. Install oil filter (for valve timing control solenoid valve) (1) in the direction shown in the figure, if removed.
Check that the oil filter does not protrude from the upper sur-
face of front cover (2) after installation.
12. Install front cover as per the following:
a. Install new O-ring (1), (2), (3) onto cylinder heads and cylinder block.
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a: φ3.4 - 4.4 mm (0.134 - 0.173 in)
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EM-70
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TIMING CHAIN
b. Apply a continuous bead of liquid gasket with tube presser(commercial service tool) to front cover as shown in the figure.
Use Genuine RTV silicone seal ant or equivalent. Refer to
GI-22, "
Recommended Chemical Products and Sealants".
c. Check again that the matching marks on timing chain and that on each sprocket are aligned. Then, install front cover.
CAUTION:
Be careful not to damage front oil seal by interference with
front end of crankshaft.
d. Tighten mounting bolts in numerical order as shown in the fig- ure.
There are three types of mounting bolts.
e. After all mounting bolts are tightened, retighten t hem in numerical order as shown in the figure.
CAUTION:
Be sure to wipe out any excessive liquid gasket leaking onto surface mating with oil pan.
13. Install valve timing control cover as per the following:
A : Junction between cylinder block and cylinder head
B : Protrusion
c : 4.3 - 5.3 mm (0.169 - 0.209 in)
d: φ3.4 - 4.4 mm (0.134 - 0.173 in)
e: φ4.0 - 5.6 mm (0.157 - 0.220 in)
f: φ4.8 - 5.8 mm (0.189 - 0.228 in)
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A : 0.79 in (0.79 in)
B : 1.77 in (1.77 in)
C : 3.15 in (3.15 in)
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