Friday, June 17, 2011

HOW to replace timing chain and tensioner on 2003 Honda Accord coupe with 2.4l I-Vtec 4-cylinder engine?

Timing Chain, Sprockets, Front Cover & Seal


Removal & Installation



Accord

NOTE
Keep the cam chain away from magnetic fields.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Note the radio security code and the radio presets. Disconnect the negative battery cable.
  3. Rotate the crankshaft to set the engine at Top Dead Center (TDC) on the compression stroke for the No. 1 piston. The TDC mark on the crankshaft pulley should line up with the pointer.
  4. Raise and support the vehicle safely. Remove the front tires. Remove the splash shield. Lower the vehicle.
  5. Remove the drive belt. Remove the cylinder head cover. Remove the crankshaft pulley.
  6. Check that the number one piston TDC marks on the variable timing control (VTC) actuator and exhaust camshaft sprocket are aligned.
  7. Disconnect the crankshaft position (CKP) sensor connector and the variable valve timing control (VTC) oil control solenoid valve connector.
  8. Remove the VTC oil control solenoid valve.
  9. Properly support the engine using a block of wood under the oil pan. Remove the ground cable. Remove the upper bracket. Remove the side engine mount bracket.
  10. Remove the chain case cover.
  11. Loosely install the crankshaft pulley. Turn the crankshaft counterclockwise to compress the auto tensioner. Align the holes on the lock and the auto tensioner. Insert a 0.05 inch diameter pin into the holes. Turn the crankshaft clockwise to secure the pin. Remove the auto tensioner.
  12. Remove the cam chain guide. Remove the Remove the tensioner arm.
  13. Remove the cam chain from the engine.

To install:


NOTE
Check that the VTC actuator is locked by turning the actuator counterclockwise. If not locked, turn the actuator clockwise until it stops. Recheck it. If it is still not locked, replace it.

  1. Set the crankshaft to TDC. Align the TDC mark on the crankshaft sprocket with the pointer on the engine block.
  2. Set the camshafts to TDC. The punch mark on the VTC actuator and the punch mark on the exhaust camshaft sprocket should be at the top. Align the TDC marks on the VTC actuator and the exhaust camshaft sprocket.
  3. Install the cam chain on the crankshaft sprocket with the colored piece aligned with the punch mark on the crankshaft sprocket.
    image

    Fig. Set the crankshaft to TDC. Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the cylinder block- HONDA 2.4L engine



    image

    Fig. The mark (A) on the VTC actuator and the mark (B) on the exhaust cam (C) should be at the top. Align the TDC marks (C) on the VTC actuator and exhaust cam sprockets-HONDA 2.4L engine

  4. Install the cam chain on the VTC actuator and exhaust camshaft sprocket with the punch marks aligned with the two colored pieces.
  5. Install the cam chain guide and tensioner arm. Install the auto tensioner. Install the cam chain guide. Remove the pin from the auto tensioner.

    image

    Fig. Align the holes on the lock (A) and the auto-tensioner (B), then place a 1.5mm pin into the holes. Turn the crankshaft clockwise to secure the pin HONDA 2.4L engine

  6. Replace the chain case oil seal.
  7. Remove any old gasket from the mating surfaces. Be sure these surfaces are clean and dry.
  8. Apply liquid gasket, part number 08717-004, 08718-0001, 08718-0003 or 08718-0009 evenly to the cylinder block mating surface of the chain case and to the inner threads of the holes.
    NOTE
    Do not install the parts if more than four minutes have elapsed since applying the liquid gasket. Instead, reapply after removing the previous coating material.

  9. Apply liquid gasket to the cylinder block upper surface contact areas on the chain case.
  10. Install a new O-ring on the chain case. Set the edge of the chain case on the edge of the oil pan. Install the chain case to the cylinder block.
    NOTE
    When installing the chain case, do not slide the bottom surface on the oil pan mounting surface.

  11. Continue the installation in the reverse order of the removal procedure.
  12. After assembly, wait at least thirty minutes before filling the engine with clean engine oil.
  13. Do not run the engine for at least three hours after installing the oil pan.
  14. Reprogram the crankshaft position (CKP) pattern. Run the engine until the operating temperature reaches 176 degree. With the engine stopped clear the CKP pattern. Turn the ignition switch OFF. Turn the ignition switch ON and wait thirty seconds.
  15. Road test the vehicle on a level surface. Decelerate the engine speed of 2500 rpm to 1000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  16. Stop the vehicle, but keep the engine running.
  17. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure. If complete, road test the vehicle on a level surface. Decelerate the engine speed of 5000 rpm to 3000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  18. Stop the vehicle, but keep the engine running.
  19. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure.
  20. If completed, turn the ignition switch OFF. Turn the ignition switch ON, wait thirty seconds. The learning procedure is now complete.
  21. As required, reprogram the power window control unit as follows.
  22. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  23. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  24. Repeat the above step three more times. Wait one second.
  25. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  26. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  27. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  28. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  29. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  30. Set the clock.
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