Timing Chain Repair Procedures

Removal

1. 1
   Remove the cylinder head cover. (Refer to Cylinder Head Assembly - Cylinder Head Cover)
2. 2
   Set the No. 1 cylinder to TDC (top dead center) on the compression stroke.

   1. Turn the crankshaft pulley and align its groove with the alignment mark on the timing chain cover.

      

   2. Make sure the TDC marks on the intake and exhaust CVVT sprockets are in a straight line on the cylinder head surface, as shown in the illustration. Otherwise, rotate the crankshaft one full turn (360°) or more.

      

      Do not turn the crankshaft pulley counterclockwise.

3. 3
   Remove the timing chain cover. (Refer to Valve Timing - Timing Chain Cover)
4. 4
   Remove the timing chain tensioner (A).

   

   Do not reuse a removed tensioner. If the tensioner must be reused, remove the tensioner, fully extend the piston (A), press the piston (A) fully in, and then install the stopper pin. At this time, the tensioner locking pin must be inserted in the same way as when the product was first delivered from the factory.

   

   

   

   

5. 5
   Remove the timing chain tensioner arm (A).

   

6. 6
   Remove the timing chain (A).

   

7. 7
   Remove the timing chain guide (A).

   

Inspection

1. 1
   Inspect the CVVT sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace if necessary.
2. 2
   Inspect the tensioner arm and chain guide for excessive wear, cracks, or damage. Replace if necessary.
3. 3
   Make sure the tensioner piston moves smoothly.

Installation

1. 1
   With the timing chain removed, the TDC marks on the intake and exhaust CVVT sprockets are slightly rotated from the TDC position, as shown.

   

2. 2
   Rotate the crankshaft clockwise (approximately 2-3 steps) from the TDC position (the crankshaft alignment pin (A) is at an angle of about 3° to the vertical centerline of the engine), as when rotating the intake CVVT sprocket from the TDC position.

   

3. 3
   Install the timing chain guide (A).

   Tightening Torque: 18.6 ~ 23 N·m

   

4. 4
   Install the timing chain tensioner arm (A).

   Tightening Torque: 18.6 ~ 23 N·m

   

5. 5
   Install the timing chain. Crankshaft sprocket > Timing chain guide > Intake CVVT sprocket > Exhaust CVVT sprocket

   1. Install the timing chain without slack between the crankshaft sprocket and the intake CVVT sprocket.

      

      The timing marks on each sprocket must align with the timing marks (colored links) of the timing chain when installing the timing chain.

   2. Install the timing chain on the exhaust CVVT sprocket without slack by rotating the CVVT assembly clockwise.

      

      The installation mark on the exhaust CVVT sprocket must align with the timing mark (colored link) of the timing chain when installing the timing chain. Press the timing chain links onto the exhaust CVVT sprocket to prevent the sprocket from rotating.

6. 6
   Install the automatic timing chain tensioner (A) and remove the stopper pin (B).

   Tightening torque: 9.8 ~ 11.8 N·m

   

   When reinstalling the tensioner, check the ratchet function after removing the locking pin by pushing the tensioner arm (A) fully in, as shown below. When fully retracted, the tensioner arm (A) and tensioner body (B) must not interfere with each other.

   

7. 7
   After rotating the crankshaft two turns in the normal direction (clockwise when viewed from the front), make sure the TDC marks on the intake and exhaust CVVT sprockets are aligned with the upper surface of the cylinder head.

   

8. 8
   Install the remaining parts in the reverse order of removal.

Fill the engine with engine oil. Clean the battery terminal posts and cable clamps, then assemble. Inspect for fuel leaks. After assembling the fuel line, turn the ignition ON (do not crank the engine) so the fuel pump operates for approximately two seconds to pressurize the fuel line. Repeat this procedure two or three times, then check all fuel line connections for leaks.