TIMING CHAIN REPLACEMENT



 1.In the following cases, replace the timing chain.
(1) With the timing chain tensioner removed from the cylinder head, the protrusion A of the plunger (furthermost trace of wear from tip) exceeds 26 mm.
(2) With the engine running, the abnormal sound is generated by the interference of the piston and valve.






















2.Use the spare timing chain kit (ME190551), and replace the timing chain according to the following procedure.
Timing chain kit (ME190551)

  • (A): Timing chain
  • (B): Timing chain tensioner
  • (C): Timing chain tensioner gasket
  • (D): Clip
  • (E): Joint link
  • (F): Mark plate (Blue)
  • (G): Pin
(1) Remove the power steering oil pipe mounting bolt for the front of the cylinder head, and the rocker cover.
(2)
caution Tighten the bolt securely so that the special tool fixture tool (MH063502) does not come off by the rotational torque of the timing chain.
Install the special tool (MH063502) to the cylinder head, and tighten the bolt (M6 x 15 mm) securely.
(3) Using the special tool pulley holder (MB991800) and crank pulley holder (MB992100), turn the crankshaft pulley clockwise and align the timing mark "0" of timing gear case with the timing mark of crankshaft pulley to set the cylinder No. 1 to the top dead centre of compression.
note If the hollow part of the hexagonal part of the camshaft is facing upward, the cylinder No. 1 is at the top dead centre of compression.
(4) With the cylinder No. 1 being at the top dead centre of compression, check that the timing marks of the camshaft sprocket are set to the positions as shown.
(5) Turn the crankshaft pulley clockwise, and stop the mark plate (blue, single-plate side) of the timing chain to the position as shown.
(6)
caution Insert cloth or similar materials into gap around the timing chain to prevent the parts from falling into the timing gear case.
Remove the timing chain tensioner and timing chain from the cylinder head, and install the special tool dummy tensioner (MH063553) to the cylinder head.
(7)
caution
  • If the pin cannot be pulled out, insert the joint link (E) of the timing chain kit from the front of the engine, and press and remove the pin.
  • Do not mix the removed mark plate (blue, single-plate side), pin, and chain plate with the timing chain kit.
Using the special tool chain disassembly tool (MH063555), pull out the pin of the mark plate (blue, single-plate side) of the timing chain, and remove the mark plate (blue, single-plate side) and the chain plate.
(8) Set the mark plates (blue, double-plate side) of the new timing chain (A) of the timing chain kit to the front of the engine, and connect the new timing chain (A) to the cut area of the timing chain installed to the engine using the joint link (E) and clip (D) of the timing chain kit.
(9) Remove the cloth or similar materials around the timing chain.
(10) Slowly turn the crankshaft pulley clockwise to feed the timing chain (A), and replace the timing chain installed to the engine with the new timing chain (A).
(11) When all the timing chain assembled to the engine is fed out, stop at the position where the join link (E) and the clip (D) are at the top of the camshaft sprocket.
(12) Insert the cloth or similar materials into the gap around the timing chain again, remove the joint link (E) and the clip (D), and then remove the timing chain assembled to the engine.
(13) Remove the special tool (MH063553) from the cylinder head.
(14) To both ends of the timing chain (A) newly installed to the engine, install the pin (G) of the timing chain kit from the rear of the engine.
(15) Install the mark plate (F) of the timing chain kit to the punch of the special tool riveting (MH063559).
(16) Align the pin section of pin (G) with the hole of mark plate (F), and set the special tool (MH063559).
(17) Tighten the set bolt of the special tool (MH063559) until it stops.
(18) Check that the pin protrusion of pin (G) is approximately 1 mm.
(19) Set the special tool (MH063559) in reverse, and align the mark plate (F) of timing chain (A) to the dice.
(20) Tighten the set bolt of the special tool (MH063559) to the tightening torque of approximately 29 N·m, and crimp the pin tip of the pin (G).
(21) Check if the width (b) of caulking part of pin section of pin (G) is 2 mm.
(22) Remove the punch around the timing chain, and then slightly turn the crankshaft pulley clockwise. (To apply a load to the timing chain)
(23) Check that the plunger of the new timing chain tensioner (B) of the timing chain kit is locked by the hook.
(24) Install the timing chain tensioner (B) to the cylinder head with the new timing chain tensioner gasket (C) of the timing chain kit.
(25) Turn the crankshaft pulley clockwise.
note The hook of the timing chain tensioner (B) is removed when the crankshaft pulley is turned clockwise.
(26) When the cylinder No. 1 is at the top dead centre of compression (the timing mark "0" of timing gear case is aligned with the timing mark of crankshaft pulley), check that the timing mark of camshaft sprocket is at the same position as before the operation.
(27) Remove the special tool (MH063502) from the cylinder head, install the power steering oil pipe mounting bolt for the front of the cylinder head, and the rocker cover.