Timing Chain and Chain Tensioner Removal and Installation

Timing Chain and Chain Tensioner Removal and Installation

Timing Chain and Chain Tensioner Components

Removal

NOTE:

After the timing chain has been removed, independently turning the camshaft or crankshaft beyond the allowable angle ranges shown in figure will cause interference between pistons and valves or between the valves themselves, which will cause damage to these parts and/or related parts.

Avoid turning the camshafts or crankshaft beyond the angle ranges shown in figure.










NOTE:

If it is necessary to rotate the camshaft after removing timing chain, turn crankshaft counterclockwise and position the key (1) within an angle of 30 to 90° from TDC before rotating the camshaft as shown in the following figure and keep the valves from coming in contact with the pistons.










1) Remove timing chain cover. Timing Chain Cover Removal and Installation
2) Align camshafts and crankshaft by turning the crankshaft at specific position as follows:
a) Align timing marks on CMP actuator (1) and timing mark (2) on exhaust camshaft timing sprocket with matchmark (3) on camshaft housing No.1.





b) Align timing mark (1) on crankshaft timing sprocket with matchmark (2) on lower crankcase.
3) Remove timing chain tensioner adjuster (3).
4) Remove timing chain tensioner (4).
5) Remove timing chain guide (5).
6) Remove timing chain (6) and crankshaft timing sprocket (7).






Installation

Timing Chain and Chain Tensioner Inspection
1) Turn camshaft position key slot (1) within specified range (30 - 90°) (2) in counterclockwise direction from top as shown in figure.
2) Align timing mark (3) on CMP actuator with matchmark (4) on camshaft housing No.1.
3) Align timing mark (5) on exhaust camshaft timing sprocket with matchmark (4) on camshaft housing No.1.
4) Install key (6) to key slot (1) of crankshaft.
a) Align key slot of crankshaft timing sprocket (7) with key, and then Install crankshaft timing sprocket to crankshaft.
b) Align timing mark (8) on crankshaft timing sprocket with matchmark (9) on lower crankcase.





5) Install timing chain while aligning two blue plates (2) with timing marks (1) on CMP actuator and exhaust camshaft timing sprockets.





6) Install timing chain while aligning blue plate (2) with timing mark (1) on crankshaft timing sprocket.





7) Install timing chain guide (1) and tighten timing chain guide bolts (2) to specified torque.

Tightening torque
Timing chain guide bolt (a): 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)

8) Apply engine oil to sliding surface of timing chain guide.
9) Attach spacer (4) to timing chain tensioner (3).
10) Install timing chain tensioner (3) and tighten timing chain tensioner bolt (5) to specified torque.

Tightening torque
Timing chain tensioner bolt (b): 25 Nm (2.5 kgf-m, 18.5 lbf-ft)

11) Apply engine oil to sliding surface of timing chain tensioner.
12) Make sure that all blue plates (6) are aligned with timing marks (7) on corresponding timing sprockets.





13) Screw in plunger (2) of timing chain tensioner adjuster (1) clockwise and install a retainer (3) (1.4 mm (0.055 in.) diameter wire or the like) to hold plunger in place.





14) Install timing chain tensioner adjuster (1) with a retainer.

Tighten timing chain tensioner adjuster bolts (2) to specified torque, and then remove a retainer from timing chain tensioner adjuster.

Tightening torque
Timing chain tensioner adjuster bolt (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)

15) Apply engine oil to timing chain, turn crankshaft clockwise 720°, and confirm that the following conditions have been met:
- Timing mark (4) on CMP actuator is aligned with matchmark (3) on camshaft housing No.1.
- Timing mark (5) on exhaust camshaft timing sprocket is aligned with matchmark (3) on camshaft housing No.1.
- Timing mark (6) on crankshaft timing sprocket is aligned with matchmark (7) on lower crankcase.

NOTE:
- Be sure to turn crankshaft 720°. If it is turned only 360°, the timing marks on CMP actuator and exhaust camshaft timing sprockets will not meet matchmark on camshaft housing No.1.
- After turning crankshaft 720°, the painted links of the timing chain will not be aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but this is normal.





16) Install timing chain cover. Timing Chain Cover Removal and Installation
17) Install cylinder head cover. Cylinder Head Cover Removal and Installation
18) Install oil pan. Oil Pan and Oil Pump Strainer Removal and Installation
19) Install engine assembly. Removal and Replacement