Timing Chain and Chain Tensioner Removal and Installation

Timing Chain and Chain Tensioner Removal and Installation
Reference: Timing Chain and Chain Tensioner Components

NOTE:
For identification of each cylinder, refer to Precautions for Identification of Cylinder.

Removal

CAUTION:
After timing chain is removed, never turn crankshaft and camshafts independently more than specified range ("a" and "b") as shown in figure.
If either of those shafts is turned, interference may occur between pistons and valves and valves themselves, and parts related to piston and valves may be damaged.








NOTE:
If it is necessary to rotate the camshaft after removing timing chain, turn crankshaft counterclockwise and position key (1) within specified range (30 - 90°) as shown in figure before rotating camshaft.








1) Remove timing chain cover.
2) By turning crankshaft, align camshafts and crankshaft at specific position as follows.
a) Align timing marks on CMP actuator (1) and timing mark (2) on exhaust camshaft timing sprocket with match marks (3) on camshaft housing No.1.





b) Align timing mark (1) on crankshaft timing sprocket with match mark (2) on lower crank case.
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
Reference: Timing Chain and Chain Tensioner Inspection

1) Turn crankshaft 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 match marks (4) on camshaft housing No. 1.
3) Align timing mark (5) on exhaust camshaft timing sprocket with match marks (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 match mark (9) on lower crank case.





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 Nm (0.92 kg-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 kg-m, 18.5 lbf-ft)

11) Apply engine oil to sliding surface of timing chain tensioner.
12) Make sure that all blue plated (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-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 kg-m, 8.5 lbf-ft)

15) Apply engine oil to timing chain, and then turn crankshaft clockwise fully twice, and make sure the following items.
^ Timing mark (4) on CMP actuator is aligned with match mark (3) on camshaft housing No. 1.
^ Timing mark (5) on exhaust camshaft timing sprocket is aligned with match mark (3) on camshaft housing No.1.
^ Timing mark (6) on crankshaft timing sprocket is aligned with match mark (7) on lower crank case.

NOTE:
^ Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprocket do not meet match marks on camshaft housing No.1.
^ After turning crankshaft twice, the discrimination links of timing chain are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.





16) Install timing chain cover.
17) Install cylinder head cover.
18) Install oil pan.
19) Install engine assembly.