Timing Drive Components

Timing Drive Components

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Exploded View









Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. Remove the fuel injection pump. REFER to Fuel Injection Pump .

3. Remove the engine front cover. REFER to Engine Front Cover .

4. Remove the 3 nuts and position the wiring harness support brackets aside.





5. Remove the 3 stud bolts and the fuel injection pump cover.





6. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Install 303-1565 into the rear of both of the camshaft slots as shown and tighten the retainer.





7. NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using the flats on the exhaust and intake camshaft to prevent camshaft rotation, loosen the exhaust and intake camshaft phaser and sprocket bolts.





8. Compress the timing chain tensioner in the following sequence.

1. Using a small pick, release and hold the ratchet mechanism.

2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.

3. Insert a paper clip into the hole to retain the tensioner.






9. Remove the 2 bolts and the timing chain tensioner.





10. Remove the timing chain tensioner arm.





11. Remove the 2 bolts and the timing chain guide.





12. Remove the timing chain.





Installation

1. Install the timing chain onto the 2 camshaft phaser and sprockets and the crankshaft sprocket.





2. Install the LH (Left Hand) timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).





3. Install the timing chain tensioner arm.





4. NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.

NOTICE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.





5. Using a small pick, push back and hold the ratchet mechanism.





6. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.





7. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.





8. Install the timing chain tensioner and the 2 bolts, then remove the paper clip to release the piston.
- Tighten to 10 Nm (89 lb-in).





9. NOTICE: The 303-1565 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using the flats on the camshafts to prevent camshaft rotation, tighten the 2 VCT (Variable Camshaft Timing) phaser and sprocket bolts in 2 stages.

- Stage 1: Tighten the bolt to 50 Nm (37 lb-ft)
.

- Stage 2: Tighten an additional 90 degrees
.






10. Remove 303-1565.





11. Position the fuel injection pump cover and install the 3 stud bolts in 2 stages.

- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 60 degrees.





12. Position the 2 engine wiring support brackets and install the 3 nuts.
- Tighten to 20 Nm (177 lb-in).





13. Install the engine front cover. REFER to Engine Front Cover .

14. Install the fuel injection pump. REFER to Fuel Injection Pump .