Removal: 2015 D4CB (A2) Engine Mechanical System Timing System Timing Gear Assembly Repair Procedures
Removal: 2015 D4CB (A2) Engine Mechanical System Timing System Timing Gear Assembly Repair Procedures
Removal: 2015 D4CB (A2) Engine Mechanical System Timing System Timing Gear Assembly Repair Procedures
Repair procedures
Removal
Timing Chain "C"
1. Rotate the crankshaft pulley to align the timing mark with TDC mark, in which No.1 piston locates at
the top dead center of compression stroke.
4. Holding the slot of the camshaft with the spanner, loosen the bolts for the high-pressure pump
sprocket and camshaft sprocket.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Before removing auto-tensioner "C", install a set pin (B) (Ø2.5mm steel wire) after compressing
the tensioner so that inner parts are not missing during disassembly.
10. Remove the timing chain "C"(A) with the camshaft sprocket.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Use the SST (09231-2B100) to remove the crankshaft pulley bolt, after remove the starter.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
5. To prevent the rotation of RH balance shaft(A), remove the plug(B) at the side of cylinder block and
insert the screwdriver(C) (or bolt) with an 8 mm(0.32in) diameter into the plughole more than 60 mm
(2.4in).
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Before removing auto-tensioner "B", install a set pin (Ø2.5mm wire) after compressing the
tensioner.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Before removing auto-tensioner "A", install a set pin (Ø2.5mm wire) after compressing the
tensioner.
6. Remove the timing chain "A"(B) with the high-pressure pump sprocket(A).
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover
and oil pan. (If any impurities are left at the sealing face, oil may leak after reassembly even
with the sealant application.)
Installation
Timing Chain "A"
1. Check the worn of timing chain, lever, guide and sprocket and replace them if necessary.
2. Install the crankshaft sprocket as the timing mark of crankshaft sprocket aligns with the timing mark
(A) of lower under cover(B), at which No.1 piston locates at the top dead center of compression
stroke.
In installing crankshaft sprocket, apply oil to the O ring inside the sprocket.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
3. Align the timing mark of LH balance sprocket(A) with the timing mark of timing chain lower under
cover(B).
4. Check the LH balance shaft (A) whether it is located at the right position. To prevent the rotation of
balance shaft, remove plug (B) at the side of cylinder block. Insert screwdriver (C) (or bolt) with an 8
mm (0.32in) diameter into the plughole and check whether it slides more than 60 mm (2.4in).
When the screwdriver (or bolt) depth is about 25~30mm(1~1.2in), rotate LH balance shaft
sprocket 1 revolution. And insert the screwdriver (or bolt) again to check whether it slides more
than 60mm(2.4in).
Tightening torque :
9.8~11.8 N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
6. Align the timing marks of sprocket and chain when high-pressure pump sprocket is not installed to
pump.
7. Using the chain connected to the high-pressure pump sprocket, install as the timing marks of LH
balance shaft sprocket(A) and crankshaft sprocket align with each other.
Tightening torque :
19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft)
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Tightening torque :
19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft)
11. Install the timing chain auto-tensioner "A" (A), and remove a set pin (B) from the auto-tensioner.
Tightening torque :
19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft)
After assembling timing chain, check whether chain is assembled within the rail at both sides.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
12. Remove the screwdriver (or bolt) from the plughole and install the plug(A).
Tightening torque :
14.7~21.6N.m (1.5~2.2kgf.m, 10.8~15.9lb-ft)
5. Using the chain connected to RH balance shaft sprocket, install as the timing marks(A) of crankshaft
sprocket and oil pump sprocket align with each other.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Tightening torque :
9.8~11.8N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
8. Install the timing chain auto-tensioner "B" (A), and remove the set pin (B) from the auto-tensioner.
Tightening torque :
9.8~11.8N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
Tightening torque :
33.3~39.2N.m (3.4~4.0kgf.m, 24.6~28.9lb-ft)
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
10. Remove the screwdriver(or bolt) from the plughole(A) and install the plug.
Tightening torque :
14.7~21.6N.m (1.5~2.2kgf.m, 10.8~15.9lb-ft)
11. Apply the sealant (A) at the timing chain lower front cover.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
19.6 ~ 26.5
B 8 x 70 6 EA
(2.0 ~ 2.7, 14.5 ~ 19.5)
19.6 ~ 26.5
C 8 x 50 6 EA
(2.0 ~ 2.7, 14.5 ~ 19.5)
19.6 ~ 26.5
D 8 x 40 1 EA
(2.0 ~ 2.7, 14.5 ~ 19.5)
19.6 ~ 26.5
E 8 x 22 1 EA
(2.0 ~ 2.7, 14.5 ~ 19.5)
Tightening torque :
9.8~11.8 N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Then apply the sealant additionally to prevent the oil leak to the overlapping part (T-joint: 4
points right and left of the engine), where bed plate, timing chain lower under cover, timing
chain lower front cover and oil pan overlap.
14. Install the crankshaft pulley (A) and tighten the crankshaft pulley bolt.
Tightening torque :
68.6~88.3Nm + 88~92˚(7.0~9.0kgf.m + 88~92˚, 50.6~65.1 lb.ft + 88~92˚)
Use the SST (09231-2B100) to remove the crankshaft pulley bolt, after remove the starter.
Then apply the sealant additionally to prevent the oil leak to the overlapping part (T-joint : 2
points right and left of the engine), where cylinder head, timing chain cover plate and timing
chain upper under cover overlap.
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5. Assemble the LH camshaft sprocket(A) tentatively, and align the timing mark with that of timing chain
upper under cover.
6. Align the RH camshaft dowel pin(A) with the timing mark(B) of the timing chain upper under cover.
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
7. Align the timing marks of sprocket and chain when RH camshaft sprocket is not installed to the
camshaft.
8. Using the chain connected to the RH camshaft sprocket, install as the timing marks of high-pressure
pump sprocket and LH camshaft sprocket align with each other.
Tightening torque :
A : 19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft)
B : 9.8~11.8 N.m (1.0~1.2 kgf.m, 7.2~8.7 lb-ft)
Tightening torque :
19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft)
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
12. Install the timing chain auto-tensioner "C"(A), and remove the set pin(B) from the auto-tensioner.
Tightening torque :
9.8~11.8N.m (1.0~1.2kgf.m, 7.2~8.7lb-ft)
Tightening torque :
64.7~74.5N.m (6.6~7.6kgf.m, 47.7~55.0lb-ft)
Tightening torque :
93.2~117.7N.m (9.5~12kgf.m, 68.7~86.8lb-ft)
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2015 > D4CB(A2) > Engine Mechanical System > Timing System > Timing Gear Assembly > Repair procedures
Then assemble the damper pulley to the crankshaft tentatively and align the timing mark of
the damper pulley to that of chain cover. And check whether timing mark of the camshaft
positions at the right place finally.
15. Apply the sealant (A) at the timing chain upper front cover.
Tightening torque :
19.6~26.5N.m (2.0~2.7kgf.m, 14.5~19.5lb-ft)
Replacement
Timing Chain Lower Front Cover Oil Seal
1. With the timing chain lower front cover oil seal installed, install the oil seal using the special service
tool (09214-4A000).
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