38 02

TIMING CHAIN ASSEMBLY

Chain Drive System
System Layout

D20DT D27DT

Oil injecting direction

Oil injecting direction

1. Exhaust camshaft sprocket 7. Oil pump tensioner

2. Upper guide rail 8. Oil pump sprocket
3. Intake camshaft sprocket 9. Crankshaft sprocket
4. Clamping guide rail 10. Oil nozzle
5. HP pump sprocket 11. Tensioner guide rail
6. Lower guide rail 12. Chain tensioner

ENGINE HOUSING CHANGED BY

KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
 02 39

Chain

GENERAL
1. Chain type: Double Bush
2. Pitch: 9.525 mm
3. Load limits: 19,000 N

ASSY
4. No. of links: 148 EA (D20DT), 144 EA (D27DT)
5. Overall length: 1409.7 mm (D20DT), 1371.6 mm (D27DT)
6. Replace when the chain is extended by 0.5 % from overall length (Replace if extended by over 7.0485 mm

HOUSING
(D20DT), 6.858 mm (D27DT))

Chain Tensioner

EXHAUST I N T A K E
Check valve

LUB
COOLING
* Check valve opening pressure: 0.2 ~ 0.5 bar

FUEL
The major function of tensioner is optimizing the movement of chain drive system by using spring constant and oil
pressure in the tensioner.

CONTROL
The tensioner performs function of adjusting chain tension to be always tight, not loose, while engine running. By
doing so, can reduce wears of each guide rail and sprocket.

65 ± 5.0 Nm
Tightening torque

SENSOR
(Installed on the cylinder head)

Guide Rail
Guide rail is used to optimize the movement of chain drive system like tensioner.
Guide rail can prevent chain slap when chain is extended and reduce chain wears.
Guide rail is needed especially when the distance between the sprockets are too long.
The material is plastic.

1. Location of guide rail

1) Tensioner guide rail: Between crankshaft sprocket and exhaust camshaft sprocket
2) Upper guide rail: Between exhaust camshaft sprocket and intake camshaft sprocket
3) Clamping guide rail: Between intake camshaft sprocket and HP pump sprocket
4) Lower guide rail: Between HP pump sprocket and crankshaft sprocket

CHANGED BY ENGINE HOUSING

EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN
40 02

Timing Setting

D20DT D27DT

Sprocket
marking:
Sprocket
4 points
marking:
(Gold marking) 4 points
(Gold marking)

<Timing Marking Points on Chain>

1. Check marking links on the chain (Gold marking)

2. Locate a point with two continuous marking links and align it to a marking on crankshaft sprocket ( )
3. Align respective marking link to each camshaft sprocket (intake and exhaust) marking ( )
4. Align another marking link to HP pump sprocket marking ( )

ENGINE HOUSING CHANGED BY

KYRON SM - 2005.09 EFFECTIVE DATE
AFFECTED VIN
 02 41

GENERAL
Removal and Installation

1. Remove the cylinder head assembly.

2. Remove the oil pan.

ASSY
3. Remove the chain guide rail with a sliding hammer.
4. Remove the chain cover.

HOUSING
EXHAUST I N T A K E
5. Remove the oil pump drive chain.
D20DT
6. Remove the upper guide rail while pushing the
retaining spring with a screwdriver.
7. Remove the lower guide rail.
8. Remove the oil pump drive chain.

LUB
COOLING
FUEL
D27DT

9. Remove the tensioner guide rail. CONTROL

SENSOR

10. Remove the timing chain.

11. Install in the reverse order of removal.

NOTICE
• Thoroughly clean the removed components before
installing.

CHANGED BY ENGINE HOUSING

EFFECTIVE DATE KYRON SM - 2005.09
AFFECTED VIN