Procedures

Timing Drive Components

Special Tool(s):

Material:

Removal

CAUTION: Since the engine is not free-wheeling, the timing procedures must be followed exactly or piston and valve damage can occur.

1. Remove the engine front cover.
2. Remove the crankshaft sensor ring from the crankshaft.





3. CAUTION: The caps must be marked for installation in their original location or damage to the engine can occur.

Remove the 6 bolts and remove the 3 balance shaft bearing caps.





4. Remove the balance shaft.





5. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur.

Position the crankshaft with the keyway at the 12 o'clock position.





6. Install and carefully tighten the special tool on the camshafts.





7. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.





8. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.





9. Remove the LH and RH timing chains and the crankshaft sprockets.





10. Remove the 4 bolts and the timing chain guides.





11. Remove the 2 bolts, flat washers, camshaft sprockets and RH camshaft spacer.





Installation

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

1. CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Compress the tensioner plunger, using a vise.





2. Install a retaining clip on the tensioner to hold the plunger in during installation.





3. NOTE: There are 61 links in each timing chain.

If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.





4. Install the RH camshaft spacer ring, both camshaft sprockets, flat washers and tighten the bolts in 2 stages.
^ Stage 1: Tighten to 40 Nm (30 ft. lbs).
^ Stage 2: Tighten an additional 90 degrees.





5. Install the timing chain guides and the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs).





6. NOTE: Slightly loosen the Camshaft Holding Tool to allow slight camshaft movement.

Preposition the camshafts.
1 Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
2 Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
^ Tighten the Camshaft Holding Tool to maintain camshaft prepositioning.





7. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage can occur.

Position the crankshaft with the special tool, then remove the tool.





8. Install the crankshaft sprocket, making sure the flange faces forward.





9. Install the lower end of the LH timing chain, aligning the timing marks.





10. NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.





11. CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.

NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.





12. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.





13. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole, for identification.

Position the LH and RH timing chain tensioner arms on the dowel pins and install the timing chain tensioners and the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs).





14. Remove the retaining clips from the RH and LH timing chain tensioners.





15. Check for correct alignment of all timing marks.





16. Remove the special tools from the camshafts.





17. Install the crankshaft sensor ring on the crankshaft.





18. Lubricate the balance shaft journals with clean engine oil.
19. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.





20. Position the balance shaft on the journals.





21. NOTE: It may be necessary to use an inspection mirror to view the marks.

Align the chalk mark on the balance shaft with the camshaft timing mark as shown.





22. Install the bearing caps in their original locations and tighten the 6 bolts in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs).





23. Install engine front cover.