Timing Chain: Service and Repair
Engine Front Cover, Timing Gears, Chain and Tensioners
Special Tool(s)
Material
1. Disconnect the battery ground cable.
2. Drain the engine oil.
3. Remove the valve covers.
4. If removing the timing chains, gears or other valve train components, remove the camshaft roller followers.
5. Remove the cooling fan.
6. Remove the parts in the order indicated in the illustrations and tables.
To remove individual parts, only carry out the listed steps:
Item 1: Accessory Drive Belt Removal Note
1. Rotate the belt tensioner clockwise and remove the accessory drive belt.
Item 33: Water Pump Pulley Bolts Removal Note
1. To remove the water pump pulley, use special tool 303-D055 to prevent the pulley from turning while removing the bolts.
Item 35: Crankshaft Pulley Bolt Removal Note
1. To remove the crankshaft pulley bolt, remove the upper fan shroud and electric fan.
2. Using the special tool to prevent the crankshaft pulley from turning, remove the pulley bolt.
Item 37: Crankshaft Pulley Removal Note
1. Using the special tool, remove the crankshaft pulley.
Item 38: Crankshaft Seal Removal Note
1. Using the special tool, remove the crankshaft seal.
Item 39: Engine Front Cover Removal Note
1. Remove the four oil pan-to-engine front cover bolts.
2. Remove the fasteners and the engine front cover.
3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can create leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Remove and discard the gaskets, clean and inspect the sealing surfaces.
Items 42-47: Timing Chain Tensioner Removal Note
1. CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage can occur.
CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.
Using the special tool, position the crankshaft with the keyway at the 12 o'clock position.
2. Install the special tool.
3. NOTE: RH is shown, LH is similar.
Remove the timing chain tensioning system from both timing chains.
^ Remove the bolts.
^ Remove the timing chain tensioners.
^ Remove the timing chain tensioner arms.
Items 41-78: Timing Drive Components Installation Note
1. NOTE: Compress the tensioner and install the retaining pin.
NOTE: LH tensioner is shown, RH tensioner is similar.
Install the tensioners.
2. CAUTION: Timing marks must be at the 12 o'clock position and indexed at the 6 o'clock position.
Install the camshaft sprockets and chain as an assembly.
3. Install the special tool.
4. Install the camshaft spacer, washer and bolt, and hand-tighten the bolt.
5. Install the camshaft gear, washer and bolt, and hand-tighten the bolt.
6. Tighten the bolts in two stages:
^ Stage 1: Tighten to 40 Nm (30 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.
7. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
NOTE: Steps 7-10 apply to engines with ratcheting timing chain tensioners only.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using an edge of a vise.
8. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
9. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
10. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation.
^ Remove the tensioner from the vise.
11. CAUTION: The timing chain procedures must be followed exactly or damage to valves and pistons will result.
NOTE: Steps 11 and 12 apply to engines with non-ratcheting timing chain tensioners only.
NOTE: LH shown, RH similar.
Compress each tensioner plunger, using a vise.
12. Install a retaining clip on each tensioner to hold the plunger in during installation.
13. NOTE: Steps 13 through 20 apply to all engines.
If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
14. Install the timing chain guides.
15. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position.
16. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.
CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston or valve damage will occur.
NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Using the special tool, position the crankshaft so the number one cylinder is at TDC.
17. Remove the special tool.
18. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
19. Install the LH timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
20. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arms on the dowel pin and install the LH timing chain tensioner.
21. NOTE: Step 21 applies to engines with ratcheting timing chain tensioners only.
Remove the retaining clip from the LH timing chain tensioner.
22. NOTE: Step 22 applies to engines with non-ratcheting timing chain tensioners only.
Remove the retaining clip from the LH timing chain tensioner.
23. NOTE: Steps 23 through 25 apply to all engines.
Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
24. Install the RH timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
25. Position the RH timing chain tensioner arms on the dowel pin and install the RH timing chain tensioner.
26. NOTE: Step 26 applies to engines with ratcheting timing chain tensioners only.
Remove the retaining clip from the RH timing chain tensioner.
27. NOTE: Step 27 applies to engines with non-ratcheting timing chain tensioners only.
Remove the retaining clips from the RH timing chain tensioner.
28. NOTE: Applies to all engines.
Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
Item 39: Engine Front Cover Installation Note
1. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow these instructions can result in future oil leakage.
Apply sealant in the locations shown.
2. Install the engine front cover seals and the engine front cover, and tighten the fasteners in the sequence shown.
3. Tighten the bolts in the sequence shown in three stages:
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 3: Tighten an additional 60 degrees.
Item 38: Crankshaft Seal Installation Note
1. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
2. Using the special tools, install the crankshaft seal.
Items 35-37: Crankshaft Pulley Bolt Installation Note
1. NOTE: The crankshaft pulley must be installed within four minutes after applying the sealant.
Apply sealant to the Woodruff key slot on the crankshaft pulley.
2. Using the special tool, install the crankshaft pulley.
3. Install the special tool.
4. Install the bolt and the washer. Tighten the bolt in four stages:
^ Stage 1: Tighten the bolt to 90 Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten the bolt to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten the bolt an additional 90 degrees.