Plastic Secondary Timing Chain Tensioner Failure
SeriousEngineEarly 4.0-litre AJ26 and AJ27 V8 engines utilized first- and second-generation plastic-bodied secondary timing chain tensioners. Over repeated heat cycles and exposure to acidic engine oil, the plastic body develops stress fractures and the plastic shoe breaks off. This allows the secondary timing chain to slacken and skip teeth on the camshaft sprockets, causing piston-to-valve collision that results in bent valves and catastrophic engine destruction.
Loud metallic rattle or clattering noise from the front timing cover on cold startup, Rough erratic idling with misfire codes P0300 to P0308 stored in the engine ECU, Sudden loss of compression and failure to restart after a cold start attempt
- Inspect service history for documented invoice proof of metal-bodied Gen 3 tensioner retrofits
- Remove the right-hand (bank 1) camshaft cover to visually inspect tensioner body composition
- Listen attentively with a mechanic stethoscope to the upper timing covers during cold startup