Removal And Installation

FRONT TIMING CHAIN CASE

Removal and Installation

NOTE:
- This section describes the procedure for removal/installation of the front timing chain case without removing the oil pan (upper) from the vehicle.
- When rear timing chain case must be removed, remove the engine from the vehicle. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse order of removal. Removal and Replacement.
- Exploded View for component parts location.
- When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Disconnect the battery negative terminal. Removal And Installation.
2.Remove engine under cover. Exploded View.
3.Drain the engine coolant from the radiator. Procedures.
4.Drain the engine oil. Removal and Replacement.
5.Drain the power steering fluid. Draining.
6.Remove engine room cover. Service and Repair.
7.Remove front air duct. Service and Repair.
8.Remove battery tray. Service and Repair.
9.Remove the hood ledge covers (RH and LH).
10.Remove cowl top and cowl top extension. Removal And Installation.
11.Remove upper radiator hose.
12.Disconnect engine coolant reservoir hose from the radiator and remove engine coolant reservoir.
13.Remove cooling fan assembly. Removal and Installation.
14.Disconnect lower radiator hose from engine.
15.Disconnect the power steering fluid reservoir tank hose from the power steering pump and fluid cooler and remove the power steering fluid reservoir tank. Exploded View.
16.Remove the front RH wheel and tire. Adjustment.
17.Remove the engine side under cover.
18.Remove the drive belt. Removal and Replacement.
19.Lock the drive plate using tool.






CAUTION:
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the
Tool.
20.Remove the crankshaft pulley as follows:
a.Loosen crankshaft pulley and locate bolt seating surface at 10 mm (0.39 in) from its original position.





b.Position a pulley puller at recess hole of crankshaft pulley to remove crankshaft pulley.

CAUTION:
Do not use a puller claw on crankshaft pulley periphery.
21.Remove the power steering pump. Removal And Installation.
22.Remove the generator. Removal and Installation.
23.Disconnect the A/C tubes from the A/C compressor and position aside.
24.Remove the A/C compressor bolts, remove the A/C compressor and position aside. Service and Repair.
25.Remove the generator bracket. Exploded View.
26.Support the engine with suitable jack and remove the RH engine insulator, mount and bracket. Refer to
Removal and Replacement.
27.Remove the rocker covers, if necessary. LH and RH.
NOTE:
Necessary only when removing timing chains.





28.If removing the timing chains, obtain compression TDC of No. 1
cylinder as follows:
a.Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.





b.Check that intake and exhaust camshaft lobes on No. 1 cylinder (right bank of engine) are located as shown.
- If not, turn the crankshaft one revolution (360�) and align as shown.
29.Remove engine oil cooler tube bolts and bracket.
30.Disconnect the oil pressure switch harness connector.
31.Disconnect valve timing control harness connector.





32.Remove the Bank 1 (RH) (A) and Bank 2 (LH) (B) IVT covers.
a.Loosen the IVT cover bolts in the reverse order as shown.

CAUTION:
The shaft in the IVT cover is inserted into the center hole of the intake camshaft sprocket. Remove the IVT cover by pulling straight out until the IVT cover disengages from the camshaft sprocket.
- A: Bank 1 (Conventional RH bank 1)
- B: Bank 2 (Conventional LH bank 2)
- C: Dowel pin hole b.Shaft is engaged with intake side camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged.





- The mating surface of magnet retarder (2) may be fitted with the exhaust side camshaft sprocket via engine oil. Open IVT
cover (1) carefully.
- If the mating surface of the magnet retarder is fitted with the camshaft sprocket, open the IVT cover within the range that the load is not applied to the harness. Remove it so as to prevent magnet retarder from dropping.

CAUTION:
- Be careful not to damage magnet retarder.
- When carrying IVT cover, face the magnet retarder side up to prevent the IVT cover from falling from magnet retarder.
- Never remove magnet retarder from IVT cover. (Disassembly prohibited)
33.Remove the A/C idler pulley and bracket and the drive belt auto-tensioner.
34.If necessary, remove the idler pulley and water pump cover.





35.Remove the front timing chain case.
a.Loosen the front timing chain case bolts in the order as shown.





b.Insert the appropriate size tool into the notch (A) at the top of the front timing chain case as shown.
c.Pry off the case by moving the suitable tool (B) as shown.
- Cut liquid gasket for removal using Tool.

CAUTION:
- Do not use a screwdriver or similar tool.
- After removal, handle carefully so it does not bend, or warp under a load.





36.Remove O-rings (1) from rear timing chain case.
- A: Bank 1 (RH)
- B: Bank 2 (LH)

CAUTION:
Use new O-rings for installation.





37.Remove the front oil seal from the front timing chain case using a suitable tool.

CAUTION:
Do not damage the front cover.





38.Remove all old Silicone RTV Sealant from all the bolt holes and bolts.

CAUTION:
Do not damage the threads or mating surfaces.





39.Use a scraper to remove all of the old Silicone RTV Sealant from the front timing chain case and opposite mating surfaces.

CAUTION:
Do not damage the mating surfaces.

INSTALLATION






1.Install dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
NOTE:
Be sure to place the dowel pins in original hole locations in the front timing chain case.





2.Install the new front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges.
NOTE:
Install it so that each seal lip is oriented as shown.





a.Install the new front oil seal so that it becomes flush with the face with front timing chain case using suitable drift.

CAUTION:
Press fit straight and avoid causing burrs or tilting the oil seal.
NOTE:
Make sure the garter spring is in position and seal lip is not inverted.





3.Install new O-rings (1) on rear timing chain case.
- A: Bank 1 (RH)
- B: Bank 2 (LH)

CAUTION:
- Use new O-rings for installation.
- Do not reuse O-rings.





4.Apply Silicone RTV Sealant to front timing chain case as shown.
- Use Genuine Silicone RTV Sealant, or equivalent. Recommended Chemical Products And Sealants.
- Before installation, wipe off the protruding sealant.
- C: 2.6 - 3.6 mm (0.102 - 0.142 in) dia.

CAUTION:
- Installation should be done within 5 minutes after applying liquid gasket.
- Do not fill the engine with oil for at least 30 minutes after the components are installed to allow the sealant to cure.
5.Install dowel pin on the rear timing chain case into dowel pin hole in front timing chain case.





6.Loosely install the front timing chain case bolts.






7.Tighten the front timing chain case bolts in the order as shown.
- Retighten the front timing chain case bolts in the order as shown.









8.Install upper oil pan bolts as shown. Upper Oil Pan.
9.Install lower oil pan. Lower Oil Pan.
10.Install IVT control valve covers.





a.Install new seal rings (1) in shaft grooves.
- A: Bank 2

CAUTION:
- When replacing seal rings, replace all rings with new ones on both RH and LH IVT control valve covers.
- Do not reuse O-rings.





b.Check the joint between dowel pins and dowel pin holes for excessive free play.
- A: Mating surface of magnet retarded
- B: Moves slightly
- C: Not shaken

CAUTION:
Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose.





c.Install IVT covers with a new gasket to front timing chain case.
- 1: Valve timing control cover
- 2: Magnet retarder

CAUTION:
- Never face magnet retarder side down to prevent magnet retarder from dropping.
- Check the mating surface of the magnet retarder and the drum of the exhaust side camshaft sprocket for foreign materials.
- Align center of both shaft holes of the shaft and the intake side of the intake camshaft sprocket, and then insert them.
- Be careful not to drop the seal ring from the shaft groove.
- When setting the valve timing control cover in position by hand, if valve timing control cover is not centered with the valve timing case, the dowel pin of the magnet retarder may not be aligned with the dowel pin holes of the cover. In this case, return to step "b".
d.Being careful not to move seal ring from the installation groove, align the dowel pins on the front timing chain case with the holes to install valve timing control covers.





e.Tighten bolts in the numerical order as shown.






- A: Bank 1 (Conventional RH bank)
- B: Bank 2 (Conventional LH bank)
- C: Dowel pin hole
11.Apply liquid gasket and install the water pump cover, if removed.
- Use Genuine Silicone RTV Sealant or equivalent. Recommended Chemical Products And Sealants.

CAUTION:
- Installation should be done within 5 minutes after applying liquid gasket.
- Do not fill the engine with oil for at least 30 minutes after the components are installed to allow the sealant to cure.
12.Install crankshaft pulley and tighten the bolt in two steps.
- Lubricate thread and seat surface of the bolt with new engine oil.
- For the second step angle tighten using Tool.







13.Remove the Tool attached to the starter bolt hole.







CAUTION:
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing the Tool.
14.Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
15.Installation of the remaining components is in reverse order of removal.

INSPECTION AFTER INSTALLATION

- Before starting engine, check oil/fluid levels including engine coolant and engi
- 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 and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: