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Removal and Installation
 
 
REMOVAL
noteWhen removing the timing chain, remove the engine assembly from the vehicle.
 
 
ELECTRIC INTAKE VALVE TIMING CONTROL ACTUATOR
1. Remove reservoir tank. Refer to Exploded View.Exploded View
2. Support the bottom surface of engine using a transmission jack, and then remove the rear torque rod and the engine mounting insulator (RH). Refer to Removal and Installation.
cautionWhen using the jack, apply a piece of wood to the oil pan (lower) mounting bolt to protect the bottom of engine from being scratched.
3. Disconnect the harness connectors from the electric intake valve timing control actuator.
4. Loosen electric intake valve timing control actuator bolts in reverse of the sequence shown and remove electric intake valve timing control actuator.
 
 
EXHAUST VALVE TIMING INTERMEDIATE LOCK CONTROL SOLENOID VALVE AND EXHAUST VALVE TIMING CONTROL SOLENOID VALVE
1. Remove the engine under cover. Refer to Removal and Installation.
2. Disconnect the harness connectors from the exhaust valve timing intermediate lock control solenoid valve and exhaust valve timing control solenoid valve.
3. Remove bolts and remove the exhaust valve timing intermediate lock control solenoid valve and exhaust valve timing control solenoid valve.
cautionDo not reuse O-rings.
 
 
TIMING CHAIN
cautionApply new engine oil to parts as indicated in the illustration before installation.
1. Remove the engine assembly from the vehicle. Refer to Removal and Installation.Removal and Installation
2. Secure the engine assembly to stand. Refer to Setting.Setting
3. Remove the intake manifold. Refer to Removal and Installation.Removal and Installation
4. Remove intake port insulator. Refer to Removal and Installation.
cautionDo not reuse intake port insulator gasket.
5. Remove the oil pan (upper). Refer to Removal and Installation.Removal and Installation
6. Set the No.1 cylinder at TDC on the compression stroke using the following procedure:
  1. Rotate the crankshaft pulley clockwise and align the mating mark to the timing indicator on the front cover.
    noteDo not use white marks when setting TDC.
  2. Remove the engine oil gauge.
  3. Remove the high pressure fuel pump insulator.
    Refer to Removal and Installation.Removal and Installation
  4. Disconnect the harness connectors from the ignition coils.
  5. Remove the ignition coils. Refer to Removal and Installation.Removal and Installation
  6. Disconnect harness retainers from rocker cover.
  7. Unbolt and reposition engine cover bracket.(With engine cover models) Refer to
    Removal and Installation.
  8. Loosen rocker cover bolts in reverse of the sequence shown and remove the rocker cover.
    cautionDo not reuse the rocker cover gasket.
  9. At this time, check that the both intake camshaft and exhaust camshaft cam lobes of No. 1 cylinder are oriented () as shown.
    : Engine front
    • If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
7. Disconnect the harness connectors from the exhaust valve timing intermediate lock control solenoid valve and exhaust valve timing control solenoid valve, electric intake valve timing control actuator and engine oil pressure sensor.
8. Remove the engine oil pressure sensor (if necessary).
9. Remove the exhaust valve timing intermediate lock control solenoid valve and exhaust valve timing control solenoid valve (if necessary).
10. Loosen electric intake valve timing control actuator bolts in reverse of the sequence shown and remove electric intake valve timing control actuator.
11. Unbolt ground cable and release harness retainers from front cover then reposition harness.
12. Remove the drive belt auto tensioner. Refer to Removal and Installation.Removal and Installation
13. Remove the fuel rail protector. Refer to Removal and Installation.
14. Remove crankshaft pulley using the following procedure:
  1. Hold the crankshaft pulley using suitable tool (A), then loosen and remove the crankshaft pulley bolt.
  2. Attach suitable tool (A) in the M 6 (0.24 in diameter) thread hole on crankshaft pulley , and remove crankshaft pulley.
15. Remove the front cover using the following procedure:
  1. Loosen front cover bolts in reverse of the sequence shown.
    : Dowel pin
  2. Cut liquid gasket using seal cutter [SST: KV10111100 (J-37228)] (A).
    cautionDo not damage the front cover.
  3. Remove the front cover.
    cautionDo not reuse O-rings or filter.
  4. Remove front oil seal using suitable tool.
    caution
    • Do not damage the front cover.
    • Do not reuse front oil seal.
  5. Remove the camshaft sprocket (INT) oil seal from the front cover (if necessary).
    cautionDo not reuse camshaft sprocket (INT) oil seal if removed from front cover.
  6. Remove the tension guide (upper) from the front cover (if necessary).
16. Remove timing chain tensioner using the following procedure:
  1. Push in timing chain tensioner plunger until groove is aligned with hole in tensioner body.
    • Insert a suitable tool into hole to secure plunger.
  2. Remove the timing chain tensioner.
    cautionDo not remove suitable tool from timing chain tensioner when removed from vehicle. If timing chain tensioner plunger becomes fully extended, replace timing chain tensioner.
17. Remove bolts and remove the tension guide and slack guide .
18. Remove the timing chain .
cautionDo not rotate the crankshaft or camshafts while the timing chain is removed. It can cause damage to the valve and piston.
19. Remove the camshaft sprockets using the following procedure (if necessary):
  1. Secure hexagonal part of the camshaft with a suitable tool and loosen the camshaft sprocket bolt.
    : Camshaft sprocket (INT)
    : Camshaft sprocket (EXH)
  2. Remove the camshaft sprocket bolt and camshaft sprockets for both camshafts.
20. Remove balancer unit timing chain tensioner using the following procedure:
  1. Compress clip and push in on tensioner plunger.
    Push plunger in until the end of the plunger
    is aligned with the hole
    in the balancer unit timing chain tensioner body
    .
    cautionDo not remove suitable tool from timing chain tensioner when removed from vehicle. If timing chain tensioner plunger becomes fully extended, replace timing chain tensioner.
  2. Remove the balancer unit timing chain tensioner.
21. Secure width across flats of the balancer unit LH side shaft using a suitable tool. Loosen the balancer unit sprocket bolt .
22. Remove balancer unit timing chain, balancer unit sprocket and crankshaft sprocket.
23. Loosen balancer unit bolts in reverse of the sequence shown and remove balancer unit.
cautionDo not disassemble balancer unit.
 
 
INSTALLATION
 
 
ELECTRIC INTAKE VALVE TIMING CONTROL ACTUATOR
Installation is in the reverse order of removal.
  • Tighten the electric intake valve timing control actuator bolts to the specified torque in the sequence shown.
    Electric intake valve timing control actuator bolts : 7.0 N·m (0.71 kg-m, 62 in-lb)
 
 
EXHAUST VALVE TIMING INTERMEDIATE LOCK CONTROL SOLENOID VALVE AND EXHAUST VALVE TIMING CONTROL SOLENOID VALVE
Installation is in the reverse order of removal.
cautionDo not reuse O-rings.
 
 
TIMING CHAIN
1. Make sure the crankshaft key points straight up.
2. Install the balancer unit and tighten the bolts in the numerical order as shown:
caution
  • When reusing a bolt, check its outer diameter before installation. Follow the Balancer Unit Bolt Outer Diameter procedure.
  • Make sure to install bolts in correct location because bolts are different lengths.
    Bolts 1 - 5: 172 mm (6.77 in)
    Bolt 6: 122.5 mm (4.82 in)
  • Check tightening angle with angle wrench [KV10112100 (BT-8653-A)] (A) or a protractor. Do not make judgment by visual check alone.
Step 1Bolts 1-5: 42 N·m (4.3 kg-m, 31 ft-lb)
Bolt 6: 36 N·m (3.7 kg-m, 27 ft-lb)
Step 2Bolts 1-5: 120° – 125°
Bolt 6: 90° – 95°
Step 3Loosen in reverse order : 0 N·m (0 kg-m, 0 ft-lb)
Step 4Bolts 1-5: 42 N·m (4.3 kg-m, 31 ft-lb)
Bolt 6: 36 N·m (3.7 kg-m, 27 ft-lb)
Step 5Bolts 1-5: 120° – 125°
Bolt 6: 90° – 95°
3. Install the crankshaft sprocket and the balancer unit timing chain .
  • Make sure that the crankshaft sprocket is positioned with mating marks on the block and sprocket meeting at the top.
  • Install it by lining up mating marks on each sprocket , and timing chain , .
: Pink link
: Blue link
4. Install timing chain tensioner and remove suitable tool.
  • Check matching mark position of balancer unit drive chain and each sprocket again.
5. If removed, install camshaft sprockets.
  • Secure hexagonal part of the camshaft with a suitable tool and tighten the camshaft sprocket bolts.
    Camshaft sprocket (INT) boltStep 1: 35.0 N·m (3.6 kg-m, 26 ft-lb)
    Step 2: 28° - 33°
    Camshaft sprocket (EXH) boltStep 1: 50.0 N·m (5.1 kg-m, 37 ft-lb)
    Step 2: 45° - 50°
6. Install the timing chain using the following procedure:
(1) Align the matching marks of each sprocket with the matching marks of timing chain.
Timing chainTiming chain tensionerSlack guide
Balancer unitBalancer unit timing chainBalancer unit timing chain tensioner
Crankshaft keyTension guideCamshaft sprocket (INT)
Camshaft sprocket (EXH)
Orange linkTiming markSprocket timing mark
Pink linkBlue linkTiming mark
cautionCheck matching mark position of each sprocket and timing chain again after installing the timing chain.
noteIf these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion to correct the position.
(2) Install the tension guide and slack guide .
: Timing chain
(3) Install the timing chain tensioner and remove suitable tool.
cautionDo not remove suitable tool from timing chain tensioner when removed from vehicle. If timing chain tensioner plunger becomes fully extended, replace timing chain tensioner.
(4) Check matching mark position of timing chain and each sprocket again.
7. Install new front oil seal to front cover. Refer to Removal and Installation.Removal and Installation
8. Install front cover with the following procedure:
(1) Install tension guide (upper) to front cover.
(2) If removed, install the camshaft sprocket (INT) oil seal.
cautionDo not reuse camshaft sprocket (INT) oil seal if removed from front cover.
  • Insert camshaft sprocket (INT) oil seal into the front cover to the specified depth (A) using suitable tool.
    A: 1.9 - 2.7 mm (0.075 - 0.106 in)
  • Measure the depth of the camshaft sprocket (INT) oil seal at positions and . The difference should not exceed 0.5°. Repeat measurements at positions and .
(3) Install new O-rings and filter.
cautionDo not reuse O-rings or filter.
(4) Apply a continuous bead of liquid gasket with a suitable tool to front cover as shown.
: Cylinder head
: Ladder assembly
A: 4.0 - 5.6 mm (0.16 - 0.22 in)
B: φ 2.7 – 3.7 mm (0.11 – 0.15 in)
C: Cylinder head and cylinder block mating surface
D: φ 6.0 – 7.0 mm (0.24 – 0.28 in)
E: Ladder assembly mating surface
Use Genuine RTV Silicone Sealant or an equivalent. Refer to Recommended Chemical Products and SealantsRecommended Chemical Products and Sealants.
caution
  • After tightening front cover, remove liquid gasket that protrudes at location ( ) shown.
  • Installation should be done within 5 minutes after application of liquid gasket.
  • Do not fill the engine with oil for at least 30 minutes after the components are installed to allow the liquid gasket to cure.
(5) Make sure the mating marks on the timing chain and each sprocket are still aligned. Then install the front cover.
cautionDo not damage the front oil seal or camshaft sprocket (INT) oil seal during installation.
(6) Tighten the front cover bolts to the specified torque in the sequence shown.
Front cover boltsNo. 6, 7, 8, 9, 10, 11, 13: 49 N·m (5.0 kg-m, 36 ft-lb)
Except No. 6, 7, 8, 9, 10, 11, 13: 12.8 N·m (1.3 kg-m, 9 ft-lb)
: Dowel pin
9. Install crankshaft pulley using the following procedure:
(1) When inserting crankshaft pulley with a suitable tool, tap on its center portion (not circumference).
cautionDo not damage front oil seal lip portion.
(2) Secure crankshaft pulley with a suitable tool (A).
(3) Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
(4) Tighten crankshaft pulley bolt to the specified torque.
Crankshaft bolt: 42.1 N·m (4.3 kg-m, 31 ft-lb)
(5) Tighten crankshaft pulley bolt to the specified angle using angle wrench [SST: KV10112100 (BT-8653-A)].
cautionCheck and confirm the tightening angle using angle wrench [SST: KV10112100 (BT-8653-A)]. Avoid judgment by visual inspection without Tool.
Tightening angle: 90° - 96°
(6) Check that crankshaft rotates clockwise smoothly.
10. Install the electric intake valve timing control actuator and tighten the bolts to the specified torque in the sequence shown.
11. Installation of the remaining components is in the reverse order of removal.
  • Perform "Electric intake valve timing control actuator position learning". Refer to Work Procedure.Work Procedure
  • Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control actuator is disconnected.
    Refer to Work Procedure.Work Procedure