Timing Chain: Service and Repair
Timing Chain RemovalTools Required:
DW110-060 Engine Assembly Lift Support
DW010-010 Power Pack Stand
DW110-030 Engine Overhaul Stand
DW110-130-01 Crankshaft Pulley Holder
DW110-130-02 Crankshaft Pulley Installer/Remover
DW110-150 Camshaft Sprocket Holder
DW110-190 Crankshaft Adjuster
DW110-140 Timing Chain Cover Install Guide Pin
1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine assembly.
10. Remove the flexible plate bolts and the flexible plate.
11. Support the engine assembly with the engine overhaul stand DW110-030.
12. Remove the intake manifold.
13. Remove the cylinder head cover.
14. Remove the drive belt.
15. Remove the oil pan.
16. Install the crankshaft pulley holder DW110-130-01 to the crankshaft pulley bolt.
CAUTION: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.
17. Remove the crankshaft pulley bolt using the crankshaft pulley installer/remover DW110-130-02.
18. Remove the engine mount bracket support.
19. Remove the water pump pulley.
20. Remove the drive belt automatic tensioner retaining bolts and the tensioner.
21. Remove the timing chain cover.
22. Remove two dowel rings for timing cover.
23. Remove the timing chain tensioner.
24. Remove the fixed timing chain guide.
25. Remove the timing chain lever.
26. Remove the top chain guide.
27. Remove the timing chain.
28. Remove the crankshaft sprocket and the woodruff key.
Timing Chain Installation
1. Installation should follow the removal procedure in the reverse order.
2. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using camshaft sprocket holder DW110-150.
3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
4. Adjust the crankshaft using the crankshaft adjuster DW110-190.
5. Make sure the three timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, and crankshaft sprocket respectively.
6. Install the fixed timing chain guide.
Tighten the fixed timing chain guide bolts to 18 - 22 Nm (13 - 16 ft. lbs.).
7. Install the timing chain lever.
Tighten the timing chain lever bolt to 18 - 22 Nm (13 - 16 ft. lbs.).
8. Install the timing chain tensioner.
Tighten the timing chain tensioner bolt to 18 - 22 Nm (13 - 16 ft. lbs.).
9. Install the top chain guide.
Tighten the top chain guide bolt to 9 - 11 Nm (80 - 97 inch lbs.).
10. Install two dowel rings.
11. Apply the liquid gasket (Loctite (R) 5900-118585) on the timing chain cover.
12. Install the timing chain cover install guide pin DW110-140 and position the timing chain cover.
CAUTION: Be sure the applied liquid gasket is not damaged when installing the timing chain cover.
13. Install the timing chain cover.
Tighten the timing chain cover bolt (Center) to 18 - 22 Nm (13 - 16 ft. lbs.).
Tighten the timing chain cover bolts to 6 - 10 Nm (53 - 89 inch lbs.)).
14. Install the drive belt automatic tensioner.
Tighten the drive belt automatic tensioner retaining bolt to 20 - 30 Nm (15 - 22 ft. lbs.).
15. Install the water pump pulley.
Tighten the water pump pulley bolts to 8 - 12 Nm (71 - 106 inch lbs.).
16. Install the engine mount bracket support.
Tighten the engine mount bracket support bolts to 25 - 31 Nm (18 - 23 ft. lbs.).
17. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the crankshaft pulley holder DW110-130-01 and the crankshaft pulley installer/remover DW110-130-02.
CAUTION: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.
Tighten the crankshaft pulley bolt to 500 - 600 Nm (369 - 443 ft. lbs.).
18. Install the oil pan.
19. Install the cylinder head cover.
20. Install the intake manifold.
21. Install the flexible plate.
Tighten the flexible plate bolts to 70 - 80 Nm (52 - 59 ft. lbs.).
22. Install the transaxle to the engine assembly.
23. Install the engine and transaxle assembly.