2nd Timing Chain and Chain Tensioner

Removal
1. Disconnect negative cable at battery.
2. Drain engine oil.
3. Drain coolant.
4. Remove oil pan.
5. Remove cylinder head cover.
6. Remove timing chain cover.





7. Turn crankshaft to meet the following conditions.
Note that this step must be followed for reinstallation of timing chain.
^ Key (I) (4) on crankshaft is positioned as shown.
^ Arrow mark on idler sprocket (II) (3) points upward.
^ Marks on sprockets (III) (1), (2) match with marks on cylinder head.





8. Remove timing chain tensioner adjuster No.2 (1) and gasket.
To remove them, slacken 2nd timing chain by turning intake camshaft counterclockwise a little while pushing back pad.





9. Remove intake (1) and exhaust camshaft timing sprocket (2) bolts. To remove them, fit a spanner to hexagonal part (3) at the center of camshaft to hold it stationary.





10. Remove camshaft timing sprockets and 2nd timing chain.

CAUTION: After 2nd timing chain is removed, never turn intake camshaft, exhaust camshaft and crankshaft independently more than such an extent as shown. If turned, interference may occur between piston and valves and valves themselves, and parts related to piston and valves may be damaged.

Installation





1. Check that match mark (1) on crank timing sprocket is in match with timing mark (2) on lower crankcase as shown in figure.
2. Check that arrow mark (1) on idler sprocket faces upward as shown in the figure.





3. Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head as shown in the figure.





4. Install 2nd timing chain by aligning yellow plate (1) of 2nd timing chain and match marks (2) on idler sprocket.





5. Install sprockets to intake and exhaust camshafts by aligning dark blue plate (1) of 2nd timing chain, match marks on intake sprocket and exhaust sprocket respectively.

CAUTION: Do not turn mere than allowable turning range. If turned excessively, valve and piston may get damaged.

NOTE: As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.





6. Install intake and exhaust camshaft timing sprocket bolts.
To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary.
Tightening torque
Camshaft timing sprocket bolt (a): 80 Nm (8.0 kg-m, 58.0 ft. lbs.)





7. Push back plunger (1) into tensioner body (2) and hold it at the position by inserting stopper (3) into body.
8. Install timing chain tensioner adjuster No.2 (1) and gasket.
Tightening torque
Timing chain tensioner adjuster No.2 bolt (a): 11 Nm (1.1 kg-m, 8.0 ft. lbs.)
Timing chain tensioner adjuster No-2 nut (b): 45 Nm (4.5 kg-m, 33.0 ft. lbs.)





9. Pull out stopper (2) from timing chain tensioner adjuster No.2.





10. Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block as shown in figure. Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
11. Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
12. Install timing chain cover.
13. Install cylinder head cover.
14. Install oil pan.
15. Install cooling system and other parts.
16. Refill cooling system with coolant and engine with engine oil.
17. Check to make sure that there is no water leakage and oil leakage at each connection.

Inspection

Timing Chain Guide No.2





Check shoe (2) for wear or damage.

Camshaft Sprocket





Check teeth of sprocket for wear or damage.

Timing Chain





Check timing chain for wear or damage.

Tensioner Adjuster No.2





Check shoe (1) for wear or damage.