Camshaft Timing Chain and Sprocket Replacement

Camshaft Timing Chain and Sprocket Replacement

Special Tools
* EN 46330 Timing Chain Tensioner Retaining Pin
* J 8433 Puller Bar
* J 41478 Crankshaft Front Oil Seal Installer
* J 41558 Crankshaft Sprocket Remover
* J 41665 Crankshaft Balancer and Sprocket Installer
* J 41816-2 Crankshaft End Protector
* J 42386-A Flywheel Holding Tool
* J 45059 Angle Meter

Removal Procedure




1. Remove the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement Service and Repair.
2. Remove the starter motor. Refer to Starter Replacement (V8) Service and RepairStarter Replacement (V6) Service and RepairStarter Replacement (Diesel) Service and Repair.

Caution: Refer to Fastener Caution Fastener Caution.

Note: Ensure that the teeth of the J 42386-A mesh with the teeth of the engine flywheel.

3. Install the J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation.

Tighten the J 42386-A bolts to 50 Nm (37 lb ft).




4. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned.
Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.

5. Remove and discard the camshaft sprocket bolt (206).
6. Remove the camshaft sprocket (205) and timing chain (208).




7. Remove the timing chain tension bolts (231) and tensioner (232).




8. Using the J 41816-2 (1), the J 41558 (2), bolts (3) and the J 8433 (4) in order to remove the crankshaft sprocket.




9. Remove the crankshaft sprocket (207).




10. Remove the crankshaft sprocket key, if required.

Installation Procedure




1. Install the key into the crankshaft keyway, if previously removed.




2. Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.




3. Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.




4. Use the J 41478 (1) and the J 41665 (2) in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until fully seated against the crankshaft flange.




5. Compress the timing chain tensioner guide and install the EN 46330 .





Caution: Refer to Fastener Caution Fastener Caution.

6. Install the timing chain tensioner (232) and bolts (231).

Tighten the bolts to 25 Nm (18 lb ft).





Note:
* The sprocket teeth and timing chain must mesh.
* The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly.

7. Position the camshaft sprocket (205) so the timing mark is in the 6 o'clock position.
8. Install the camshaft sprocket (205), timing chain (208), and bolt (206).




9. Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock position.




10. Remove the EN 46330 .




11. Tighten the camshaft sprocket bolt

1. Tighten the bolt a first pass to 75 Nm (55 lb ft).
2. Tighten the bolt a final pass an additional 50 degrees using J 45059 .




12. Remove the J 42386-A (1) and bolts.
13. Install the starter motor. Refer to Starter Replacement (V8) Service and RepairStarter Replacement (V6) Service and RepairStarter Replacement (Diesel) Service and Repair.
14. Install the oil pump. Refer to Oil Pump, Screen, and Crankshaft Oil Deflector Replacement Service and Repair.