Replace - Engine Removed

1. Remove engine from vehicle.

Flywheel Timing Marks-Bellhousing Removed:

Camshaft Timing Mark:

2. Remove camshaft cover. Align camshafts and flywheel at TDC as shown.

Removing Oil Pump:

3. Remove crankshaft pulley and oil pump.
4. Remove the water pump pulley.

Removing Timing Cover:

5. Remove timing cover bolts and remove cover complete with water pump and hoses.
6. Remove upper timing chain guide.

Camshaft Sprocket Bolts:

7. Hold camshafts stationary and loosen two cam sprocket bolts. A 19mm open-end wrench can be used on camshaft flats to hold it.

Removing Chain Tensioner:

8. Remove chain tensioner assembly from cylinder head.

Removing Camshaft Sprockets:

CAUTION: Do not rotate camshafts or crankshaft with timing chain removed. Piston and/or valve damage may result.

9. Remove timing chain and sprockets.
10. Inspect chain guides, sprockets, and tensioner. Replace worn or damaged parts as necessary.

CAUTION: Be sure to center timing chain on chain guides.

11. Ensure that all timing marks are aligned at TDC. Fit timing chain and exhaust camshaft sprocket. Be sure chain is tight between camshaft sprocket and crankshaft sprocket.
12. Fit intake camshaft sprocket. Keep chain tight between camshaft sprockets. Fit sprocket bolts and tighten by hand.

Resetting Chain Tensioner:

NOTE: There are two types of tensioners used. Early style tensioners preset by pushing the spring-loaded piston all the way in and turning it until it locks. Late style tensioners have a ratcheting mechanism. They can be preset by removing small bolt and spring at end of tensioner. Raise the ratcheting pawl and push the lever in all the way.
Ratcheting type tensioner can be fitted to early engines. Service and Repair

13. Preset chain tensioner so it will not apply tension to chain when installed.
14. Fit tensioner to cylinder head. Service and Repair

Resetting Chain Tensioner, Early Type.:

15. Tension timing chain.
Early type: Press on upper part of guide rail.

Fitting Center Bolt And Spring, Late Type.:

Fig. 1 Timing Chain Tensioner, Late Type.:

Late Type: Fit center bolt and spring. New units have a safety pin installed. Do not remove safety pin until tensioner is installed. Tighten center bolt to: 22 Nm (16 ft lb).

Camshaft Timing Marks:

16. Turn crankshaft by hand two full turns in direction of normal engine rotation. Recheck all timing marks at TDC for proper alignment. Reset timing chain if any fault is found.

CAUTION: It is easy for the chain to be off one tooth. Check marks very carefully.

17. Remove cam sprocket bolts one at a time, apply suitable thread locking compound and refit. Hold camshaft stationary and tighten bolts to: 65 Nm (48 ft lb).
18. Refit timing cover with water pump. Tighten cover bolts to: 20 Nm (15 ft lb).
19. Refit water pump pulley.
17. Refit oil pump and crankshaft pulley. Be careful not to damage crankshaft oil seal when fitting oil pump. Tighten crankshaft bolt to: 190 Nm (140 ft lb).
20. Refit valve cover. Tighten valve cover bolts to: 15 Nm (11 ft lb).
21. Refit engine. .