Crankshaft Gear/Sprocket: Service and Repair
REMOVAL1. Remove valve covers, oil pan and engine front cover.
CAUTION: At no time, when the timing chain(s) are removed and the cylinder heads are installed, may the crankshaft and/or camshafts be rotated. Failure to follow these directions will result in valve and/or piston damage.
NOTE: Because this is not a free-wheeling engine, if it has "jumped time," there will be damage to the valves and/or pistons and will require the removal of the cylinder heads. The camshaft sprockets should only be disassembled from the camshafts when one of the components is to be replaced.
2. Remove crankshaft position sensor pulse wheel.
3. Rotate engine to No. 1 top dead center (TDC).
4. Install Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A on flats of camshafts.
NOTE:
^ This will prevent accidental rotation of the camshafts.
^ Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A must be installed on camshaft to prevent camshaft from rotating.
5. Remove two bolts retaining RH timing chain Tensioner to cylinder head and remove timing chain tensioner.
6. Remove RH timing chain tensioner arm.
7. Remove two bolts retaining RH timing chain guide to cylinder head and remove timing chain guide.
8. Remove RH timing chain from camshaft sprocket and crankshaft sprockets.
9. Remove two bolts retaining LH timing chain tensioner to cylinder head and remove timing chain tensioner.
NOTE: Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A must be installed on camshaft to prevent camshaft from rotating.
10. Remove LH timing chain tensioner arm.
11. Remove two bolts retaining LH timing chain guide to cylinder head and remove timing chain guide.
12. Remove LH timing chain from camshaft sprocket and crankshaft sprocket.
13. If necessary, remove camshaft sprockets and crankshaft sprockets.
14. Inspect the plastic running face on timing chain tensioner arms and timing chain guides. If worn or damaged, remove and clean oil pan and oil pump screen cover and tube.
CAUTION: Do not rotate crankshaft and/or camshafts. Engine damage may occur.
INSTALLATION
1. Install timing chain guides (both sides). Install timing chain guide retaining bolts. Tighten to 8-12 Nm (71-106 inch lbs.).
NOTE:
^ If engine has "jumped time," make sure that all repairs to engine components and/or valve train have been made. Then rotate engine counterclockwise 45 degrees. This will position all pistons below top of deck face. Install cylinder heads.
^ Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A must be installed on camshafts to prevent camshafts from rotating.
2. If removed, position LH camshaft sprocket spacer and sprocket on camshaft.
3. Install washer and camshaft sprocket retaining bolt. Do not tighten at this time.
4. If removed, position RH camshaft sprocket spacer and sprocket on camshaft.
5. Install washer and camshaft sprocket retaining bolt. Do not tighten at this time.
Fig. 26 Crankshaft Sprocket Position:
6. If removed, install LH crankshaft sprocket.
NOTE:
^ Crankshaft sprockets are identical. They may only be installed one way. Refer to the illustration for proper crankshaft sprocket installation.
^ Make sure tapered part of crankshaft sprocket faces away from cylinder blocks.
Timing Chain Marks:
7. Install LH timing chain on camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of camshaft sprocket.
NOTE: If copper links of timing chain are not visible, split both timing chains in half and mark the two opposing links as shown.
8. Install LH timing chain on crankshaft sprocket. Make sure copper link of timing chain lines up with timing mark of crankshaft sprocket.
9. If removed, install RH crankshaft sprocket.
NOTE: Make sure tapered part of crankshaft sprocket faces toward cylinder blocks.
10. Install RH timing chain on camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of camshaft sprocket.
11. Install RH timing chain on crankshaft sprocket. Make sure copper link of timing chain lines up with timing mark of crankshaft sprocket.
12. Install RH and LH timing chain tensioner and secure with two bolts on each. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
13. Install Crankshaft Holding Tool T93P-6303-A over crankshaft and engine front cover alignment dowel, to position crankshaft.
14. Lubricate timing chain tensioner arm contact surfaces with clean engine oil and install RH and LH timing chain tensioner arms on their dowels.
15. With a suitable C-clamp around the timing chain tensioner arm and timing chain guide, remove all slack from timing chain. Use caution not to bend the timing chain guide.
16. Remove lock pins from timing chain tensioners and make sure all timing marks are aligned.
17. Using Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A, align camshaft, tighten camshaft sprocket bolt to 110-130 Nm (81-95 ft. lbs.).
18. Install Rotunda Dial Indicator with Bracketry 014-00282 or equivalent in cylinder No.1 spark plug hole. Check that camshaft is at maximum lift for the intake valve at 114 degrees after top dead center (TDC).
NOTE: If not at maximum lift, loosen camshaft sprocket bolt and repeat Steps 12-15.
19. Remove Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91 P-6256-A and Crankshaft Holding Tool T93P-6303-A.
20. Install engine front cover, oil pan and valve covers.
21. Start engine and check for leaks and proper operation.