Timing Chain: Service and Repair

TIMING CHAIN

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait for at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

NOTICE: After the engine switch is turned off, the HDD navigation system requires approximately 6 minutes to record various types of memory and settings. As a result, after turning the engine switch off, wait 6 minutes or more before disconnecting the cable from the negative (-) battery terminal.

3. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
(a) Remove the timing chain cover.

4. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily tighten the pulley set bolt.
(b) Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

HINT: If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

5. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.

7. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)
(a) Remove the 2 bolts and chain vibration damper.

8. REMOVE CHAIN SUB-ASSEMBLY (for Bank 1)
(a) While pushing down the No. 3 chain tensioner, insert a pin of diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

(b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12mm hexagon wrench.

NOTICE:
^ Be careful not to damage the cylinder head with the wrench.
^ Do not disassemble the camshaft timing gear.

(c) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

NOTICE: Be careful not to damage the cylinder head with the wrench.

(d) Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear assembly, camshaft timing exhaust gear assembly and crankshaft timing sprocket.
(e) Remove the No. 1 and No. 2 chains from the gears.

9. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Remove the 2 bolts and chain tensioner.

10. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate hole.

12. REMOVE NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)
(a) Remove the 2 bolts and vibration damper.

13. REMOVE CHAIN SUB-ASSEMBLY (for Bank 2)
(a) While raising up the No. 2 chain tensioner, insert a pin of diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

(b) Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt with a 12 mm hexagon wrench.

NOTICE:
^ Be careful not to damage the cylinder head with the wrench.
^ Do not disassemble the camshaft timing gear.

14. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Remove the 2 bolts and chain tensioner.

INSPECTION

1. INSPECT CHAIN SUB-ASSEMBLY
(a) Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown the illustration.
(b) Using a vernier caliper, measure the length of 15 pins.
Maximum chain elongation: 136.9 mm (5.389 in.)
If the elongation is greater than the maximum, replace the chain.

NOTICE: Perform the measurement at 3 random places.

2. INSPECT NO. 2 CHAIN SUB-ASSEMBLY
(a) Using a spring scale, pull the chain with a force of 147 N (15 kgf, 33 lbf) as shown the illustration.
(b) Using a vernier caliper, measure the length of 15 pins.
Maximum chain elongation: 137.6 mm (5.417 in.)
If the elongation is greater than the maximum, replace the chain.

NOTICE: Perform the measurement at 3 random places.

3. INSPECT CRANKSHAFT TIMING GEAR
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/chain): 61.4 mm (2.417 in.)

HINT: The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the chain and sprocket.

4. INSPECT CRANKSHAFT TIMING SPROCKET LH
(a) Wrap the chain around the sprocket.
(b) Using a vernier caliper, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/chain): 61.4 mm (2.417 in.)

NOTICE: The vernier caliper must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the chain and sprocket.

5. INSPECT NO. 1 CHAIN TENSIONER ASSEMBLY
(a) Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
If necessary, replace the chain tensioner.

6. INSPECT NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth: 0.9 mm (0.035 in.)
If the depth the is greater than the maximum, replace the chain tensioner.

7. INSPECT NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Check that the plunger moves smoothly.
(b) Measure the worn depth of the chain tensioner.
Maximum depth: 0.9 mm (0.035 in.)
If the depth is greater than the maximum, replace the chain tensioner.

8. INSPECT CHAIN TENSIONER SLIPPER
(a) for Bank 1:
(1) Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain tensioner slipper.

(b) for Bank 2:
(1) Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain tensioner slipper.

9. INSPECT NO. 1 CHAIN VIBRATION DAMPER
(a) for Bank 1:
(1) Measure the worn depth of the chain vibration damper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain vibration damper.

(b) for Bank 2:
(1) Measure the worn depth of the chain vibration damper.
Maximum depth: 1.0 mm (0.039 in.)
If the depth is greater than the maximum, replace the chain vibration damper.

INSTALLATION

1. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) While raising up the No. 2 chain tensioner, insert a pin of diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

2. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

3. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)
(a) Install the vibration damper with the 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

4. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)

HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

5. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(c) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(d) Remove the hexagon wrench from the chain tensioner.

6. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) While pushing down the No. 2 chain tensioner, insert a pin of diameter 1.0 mm (0.039 in.) into the hole to fix it in place.

7. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.

HINT: The crankshaft timing gear and camshaft exhaust gear assembly will be installed with the No. 1 and No. 2 chains connected to the gears.

(d) Install the crankshaft timing gear to the crankshaft.
(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.
(f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

NOTICE: Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

(g) Remove the pin from the No. 2 chain tensioner.

8. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)

HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner.

9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

10. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)
(a) Install the vibration damper with the 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) Remove the hexagon wrench from the No. 1 chain tensioner.

11. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY
(a) for Bank 1:
(1) Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf)

(3) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

(b) for Bank 2:
(1) Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque: 79 N*m (806 kgf*cm, 58 ft.*lbf)

(3) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

12. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily install the crankshaft pulley bolt.
(b) Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.
(c) Remove the crankshaft pulley bolt.

13. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
(a) Install the timing chain cover.