Removal
1. Remove the ground cable from the battery. Remove the head cover.
2. Set the piston of the first cylinder to the top dead center in the compression stroke and fix the crankshaft.
3. To improve access to the fuel pump sprocket cover, follow these steps:
- remove the air filter housing and front exhaust pipe;
- remove the auxiliary drive belt;
- unscrew the nut securing the power unit support on the right side of the engine, lift the engine as much as possible so as not to deform the hoses and tubes.
4. Remove the upper and lower chain tensioners.
5. Remove the tensioner pulley support post, lower and support plate pivot bolt, and remove the tensioner from the engine.
6. Remove the bolts and remove the fuel pump sprocket cover.
7. Install the locking pins into the fuel pump and camshaft sprockets.
8. Remove the bolts and remove the upper chain guide from the top of the cylinder head.
Warning: Before unscrewing the upper chain guide bolts, they must be heated to soften the compound that prevents the bolts from being loosened.
9. Heat the top chain guide bolts to make them easier to remove.
10. Unscrew the upper chain guide mounting bolts.
11. Remove the upper chain guide.
12. Using a wrench, secure the camshaft from turning and loosen the camshaft sprocket mounting bolt.
13. Check that the chain is correctly positioned on the camshaft sprocket and, using soft wire, tie the chain to the sprocket. If blocking pins are used, remove them before loosening the sprocket mounting bolts and reinstall them after loosening the bolt.
14. Remove the fuel pump locking pins and loosen the bolts securing the fuel pump sprockets to the pump boss. Remove the bolts and remove the fuel pump sprocket.
15. Remove the chain from the fuel pump sprocket, then remove the sprocket from the camshaft and remove it and the chain from the top of the cylinder head.
Lower chain and sprockets
16. Remove the top chain and sprockets.
17. Remove the chain cover.
18. Place alignment marks on the chain and sprockets.
19. Remove the fuel pump sprocket together with the chain.
20. Remove the sprocket from the crankshaft.
21.. Remove the woodruff key from the crankshaft.
Examination
1. Check the condition of the sprocket teeth for wear and damage. If there are any defects in the sprockets, the sprockets and chain must be replaced.
2. Check the condition of the chain guides and tensioner blade for wear or damage.
Installation Warning: When installing the camshaft sprocket and new chain guide, new bolts must be used.
Upper chain and sprockets
1. If new parts are installed, transfer the alignment marks from the previously installed parts to them. Check that the crankshaft is locked in the top dead center position of the piston of the first cylinder. Install the fuel pump sprocket with the chain through the top of the cylinder head.
2. Install the fuel pump sprocket and place the chain on it.
3. Check that the marks made earlier are aligned and install the fuel pump sprocket and camshaft. Remove the wire that ties the chain to the camshaft sprocket.
4. Align the timing mark on the fuel pump sprocket with the hole in the pump boss and tighten the mounting bolts finger tight.
5. Install the new camshaft sprocket bolt and tighten it finger tight.
6. Install the lower chain tensioner.
7. Install the upper chain guide and secure with bolts, tightening them to the specified torque.
8. Install the pump, camshaft and crankshaft locking pins. Adjust the timing drive if necessary
9. Install the upper chain tensioner.
10. Check that the mating surfaces of the fuel pump sprocket cover and chain cover are clean and dry. Install the cover using a thin gasket or a thin layer of sealant. Tighten the cover mounting bolts to the specified torque.
11. Install the drive belt tensioner mechanism.
12. Refit the right powertrain mount to the cylinder head.
13. Install the cylinder head cover.
14. Install the front exhaust pipe, air cleaner housing and crankshaft sensor.
Lower chain and sprockets
15. When installing new parts, transfer the alignment marks from the previously removed parts to them.
16. Install the woodruff key into the crankshaft keyway and install the crankshaft sprocket, aligning the sprocket keyway with the woodruff key.
17. Check that the fuel pump sprocket is correctly aligned and that the engine crankshaft is locked at the top dead center position of the piston of the first cylinder.
18. Check the alignment of the marks, install the chain on the fuel pump sprocket and install the sprocket in place. Check that all marks made before removal are correctly aligned.
19. Install the chain cover and install the upper timing chain.
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