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To answer some of your specific questions :
There are two chains, and two chain tensioners. The outermost is the balance chain and tensioner, which is all contained under the timing cover (the thing all the pulleys are bolted to). The timing chain (the one that's visible running over the big cam sprockets when you remove the valve cover) has it's tensioner screwed into the back of the head.
You can change the timing chain tensioner easily as a part of the HG job. You'll have to remove it anyway to remove the timing chain when you pull the head. Use a 27mm deep well socket to turn it out. Changing the balance chain tensioner is a different issue, though. You will have to remove the timing cover to do that.
Removing the timing cover will involve removing the following additional parts (not counting what you would have to remove to pull the head):
1. water pump
2. A/C compressor, and A/C compressor bracket (actually, you would probaly remove these to pull the head anyways)
3. P/S pump and bracket
4. crank pulley (27mm - do not even attempt without a heavy duty impact driver)
5. serpentine belt tensioner assembly
6. 15 T-40 torx bolts
7. 2 T-40 torx bolts from the oil pan
8. 1 ginormous circlip that hold on the oil pump cover (not technically necessary, but I'd recommend at least inspecting the oil pump gears)
Once inside the timing case, the real trouble spot is the balance chain idler gear. It's held on with a countersunk T-40 bolt. Given it's location, it'll be tough to get at it straight on, and will likely strip. Plan on ordering a new bolt (available from eeuroparts and others) ahead of time and have a screw extractor handy.
My chain guides were definitely worn, but I think the vast majority of the slack was caused by chain stretch in my case. Guides are relatively cheap, and knowing that plastic gets brittle with age, I didn't want to risk that failure, having come this far into the repair already.
The sprockets all looked good in my case, so I opted to re-use the balance sprockets, but I am installing the timing sprockets, since they come in the kit.
You can actually just clean and re-use the tensioners if you like. My balance chain tensioner was pretty sticky, and had a good varnish on it. After some serious cleaning with a degreaser and brake cleaner, it works smoothly now. I was similarly able to clean the timing tensioner.
Also, be sure to pull the oil thermostat (the 17mm cap on the bottom right of the timing cover) and clean that out thoroughly. Under the cap, there's a spring and a valve that looks kind of like a tappet. Make sure these don't show signs of wear, and replace if necessary.
posted by 71.36.88...
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