2ND Timing Chain and Chain Tensioner Removal and Installation
2nd Timing Chain and Chain Tensioner Removal and InstallationCAUTION: 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.
Removal
1. Remove timing chain cover.
2. Turn crankshaft clockwise to meet the following conditions.
^ Mark on crank sprocket match with mark on lower crankcase (I).
^ Arrow mark on idler sprocket points upward (II).
^ Marks on cam sprockets match with marks on cylinder head (III).
3. 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.
4. Remove intake and exhaust camshaft timing sprocket bolts (1). To remove them, fit a spanner (4) to hexagonal part (3) at the center of camshaft to hold it stationary.
5. Remove camshaft timing sprockets and 2nd timing chain (2).
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 figure.
3. Check that knock pins of intake (2) and exhaust (3) camshafts are aligned with timing marks on cylinder head as shown in figure.
4. Install 2nd timing chain by aligning yellow plate (1) of 2nd timing chain and match marks on idler sprocket.
5. Install sprockets to intake and exhaust camshafts by aligning dark blue plate of 2nd timing chain, match marks on intake sprocket and exhaust sprocket respectively.
CAUTION: Do not turn more than allowable turning range. If turned excessively, valve and piston may be damaged.
NOTE: As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.
6. Tighten intake and exhaust camshaft timing sprocket bolts (1) to specified torque. To tighten it, fit a spanner (2) to hexagonal part (3) at the center of camshaft to hold it stationary.
Tightening torque
Camshaft timing sprocket bolt a: 80 Nm (8.0 kgf-m, 57.5 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) with new gasket.
Tightening torque
Timing chain tensioner adjuster No.2 bolt a: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
Timing chain tensioner adjuster No.2 nut b: 45 Nm (4.5 kgf-m, 33.0 ft. lbs.)
9. Pull out stopper (2) from timing chain tensioner adjuster No.2.
10. Turn crankshaft two rotations clockwise, and then align timing mark (1) on crankshaft and timing mark (2) on cylinder block as shown in figure.
At this time, check timing marks (3, 5 and 7) of sprockets are in match with timing marks (4, 6 and 8) of cylinder head, cylinder block and lower crank case.
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 engine assembly to vehicle.