Timing Chain: Service and Repair
Camshaft Timing Chain and Sprocket Replacement
Tools Required
* EN 47519 , DW117 (DW110-060) Universal Engine Support Fixture
* J 39580 (DW010-010) Power Pack Stand Engine and Transaxle Assembly Support Remover/Installer
* OTC 1726 (DW110-030) Engine Overhaul Stand
* EN-47610 (DW110-130-01) Crankshaft Pulley Holder
* EN-47611 (DW110-130-02) Crankshaft Pulley Installer/Remover
* EN-47612 (DW110-140) Timing Chain Cover Install Guide Pin
* EN-47613 (DW110-150) Camshaft Sprocket Holder
* EN-47617 (DW110-190) Crankshaft Adjuster
Removal Procedure
1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
Caution:
Refer to Battery Disconnect Caution Battery Disconnect Caution in Cautions and Notices.
3. Disconnect the negative battery cable.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling (2.5L) Service and Repair.
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
9. Remove the engine assembly using the J 39580 (1). Refer to Engine Replacement Removal and Replacement.
10. Remove the flexible plate bolts and the flexible plate.
11. Support the engine assembly with the OTC 1726.
12. Remove the intake manifold. Refer to Intake Manifold Replacement Service and Repair.
13. Remove the cylinder head cover. Refer to Cylinder Head Cover Replacement Service and Repair.
14. Remove the drive belt.
15. Remove the oil pan. Refer to Oil Pan Replacement Service and Repair.
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.
16. Install the EN-47610 (1) to the crankshaft pulley bolt.
17. Remove the crankshaft pulley bolt using the EN-47611 (2).
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 2 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.
Installation Procedure
1. Install the crankshaft sprocket and the woodruff key.
2. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using the EN-47613 (1).
3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
4. Adjust the crankshaft using the EN-47617 (1).
5. Make sure the 3 timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, ant crankshaft sprocket respectively.
Notice:
Refer to Fastener Notice Fastener Notice in Cautions and Notices.
6. Install the fixed timing chain guide.
Tighten the fixed timing chain guide bolts to 20 Nm (15 lb ft).
7. Install the timing chain lever.
Tighten the timing chain lever bolt to 20 Nm (15 lb ft).
8. Install the timing chain tensioner.
Tighten the timing chain tensioner bolt to 20 Nm (15 lb ft).
9. Install the top chain guide.
Tighten the top chain guide bolt to 10 Nm (89 lb in).
10. Install 2 dowel rings.
11. Apply the liquid gasket Loctite(R) 5900-M8585 on the timing chain cover.
Important:
Be sure the applied liquid gasket is not damaged when installing the timing chain cover.
12. Install the EN-47612 (1) and position the timing chain cover.
13. Install the timing chain cover.
* Tighten the timing chain cover center bolt to 20 Nm (15 lb ft).
* Tighten the timing chain cover bolts to 8 Nm (71 lb in).
14. Install the drive belt automatic tensioner.
Tighten the drive belt automatic tensioner retaining bolt to 25 Nm (18 lb ft).
15. Install the water pump pulley.
Tighten the water pump pulley bolts to 10 Nm (89 lb in).
16. Install the engine mount bracket support.
Tighten the engine mount bracket support bolts to 28 Nm (21 lb ft).
17. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the EN-47610 (1) and the EN-47611 (2).
Tighten the crankshaft pulley bolt to 550 Nm (406 lb ft).
18. Install the oil pan. Refer to Oil Pan Replacement Service and Repair.
19. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement Service and Repair.
20. Install the drive belt.
21. Install the intake manifold. Refer to Intake Manifold Replacement Service and Repair.
22. Install the flexible plate.
Tighten the flexible plate bolts to 75 Nm (55 lb ft).
23. Mount the engine on the J 39580 (1).
24. Install the transaxle to the engine assembly.
25. Install the engine and transaxle assembly. Refer to Engine Replacement Removal and Replacement.
26. Install the fuel pump fuse.
27. Connect the negative battery cable.
28. Refill the crankcase with engine oil.
29. Refill the engine coolant system. Refer to Cooling System Draining and Filling (2.5L) Service and Repair.
30. Fill and bleed the power steering system. Refer to Power Steering System Bleeding Power Steering System Bleeding in Power Steering System.
31. Refill the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.