Camshaft Position Actuator Replacement - Intake

Camshaft Position Actuator Replacement - Intake
Tools Required
^ J45027 Tensioner Tool
^ J45059 Angle Meter

Removal Procedure

Important: The timing chain has 2 matching colored links and 1 uniquely colored link.





1. Remove the camshaft cover.
2. Remove the engine front cover.
3. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link (2) at the 5 o'clock position.
4. Lower the vehicle.





5. Ensure that the timing mark (4) on the intake camshaft actuator is aligned with the blue colored link (1) at the 2 o'clock position.





6. Ensure that the timing mark (3) on the exhaust camshaft actuator is aligned with the pink colored link.





7. Remove the timing chain tensioner.





8. Remove the upper timing chain guide bolts and guide.





9. Remove and discard the intake camshaft actuator bolt (2).
10. Remove the intake camshaft actuator (3).

Installation Procedure

Important:
^ There are 3 colored links on the timing chain. Two links are of matching color and one link is of a unique color. Use the following procedure to line up the links with the sprockets. Orient the chain so that the colored links are visible.
^ Always use NEW actuator bolts.





1. Assemble the intake camshaft actuator (3) to the timing chain with the timing mark (4) lined up with the blue colored link (1). Install and hand tighten a NEW intake camshaft actuator bolt (2).





2. Notice: Refer to Fastener Notice.

Install the upper timing chain guide and bolts.
Tighten the bolts to 10 Nm (89 inch lbs.).
3. Using a 24 mm wrench, engage the hex on the intake camshaft, Using a torque wrench, tighten the camshaft actuator bolt.
Tighten the bolt to 85 Nm (63 ft. lbs.), plus an additional 30 degrees using the J45059.





4. Remove the old oil from the timing chain tensioner.
5. Inspect the timing chain tensioner for scoring or free movement.
6. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
7. Measure the timing chain tensioner assembly from end to end. A NEW tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 inch) from end to end (a). A tensioner in the active state will measure 85 mm (3.35 inch) from end to end (a).





8. If the timing chain tensioner is not in the compressed state, perform the following steps:
1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
2. Install the J45027-2 (2) into a vise.
3. Install the notch end of the piston assembly into the J45027-2 (2).
4. Using the J45027-1 (1), turn the ratchet cylinder into the piston.





9. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris with a lint free cloth.
10. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
11. At the point the tension should measure approximately 72 mm (2.83 mm) from end to end (a). If the tensioner does not measure 72 mm (2.83 mm) from end to end (a) repeat steps 8.1 through 8.4.





12. Ensure that all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
13. Install the timing chain tensioner
Tighten the tensioner to 75 Nm (66 ft. lbs.).
14. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 inch) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam chest to rest on the cam chain, then give a sharp jolt diagonally downwards to release the tensioner.





15. Ensure that the timing mark (4) on the intake camshaft actuator is still aligned with the blue colored link (1) at the 2 o'clock position.





16. Ensure that the crankshaft sprocket mark still aligns with the matching colored link (2) at the 5 o'clock position.
17. Install the engine front cover.
18. Install the camshaft cover.