Removal & Installation
Compress the tensioner using a soft-jawed vice.
- While holding the ratchet mechanism with a pick, push the ratchet arm back into the tensioner housing.
Install a paper clip on the tensioner to hold the plunger in during installation.
NOTEThere are 61 links in each timing chain.
- If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
On engines equipped with bolt-on sprockets, install the camshaft sprocket bolt. Tighten the bolt as follows:
M10 bolt: Tighten in two stages.
Stage 1: Tighten to 40 Nm (30 ft. lbs.).
- M12 bolt: Tighten to 120 Nm (90 ft. lbs.).
- M10 bolt: Tighten in two stages.
Install the timing chain guides. Torque to 89 inch lbs. (10 Nm).
NOTESlightly loosen the Camshaft Holding Tool to allow slight camshaft movement.
- Rotate the left camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
Rotate the right camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
Tighten the Camshaft Holding Tool to maintain camshaft pre-positioning.
WARNINGRotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage can occur.
Position the crankshaft with the special tool, remove the tool.
Install the crankshaft sprocket, marking sure the flange faces forward.
Install the lower end of the left (inner) timing chain, aligning the timing marks.
NOTEBe sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust.
Install the left timing chain on the camshaft sprocket with the two chain (marked) links and the timing marks aligned.
WARNINGThe camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.
NOTEBe sure the chain link and crankshaft sprocket timing marks are aligned.
NOTEThe lower half of the timing chain must be positioned above the dowel.
Install the right (outer) timing chain on the crankshaft sprocket.
Position the timing chain on the camshaft sprocket. Make sure the two copper-colored (marked) links align with the camshaft sprocket timing mark.
NOTEThe left timing chain tensioner arm has a bump near the dowel hole, for identification.
- Position the left and right timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts. Torque to 18 ft. lbs. (25 Nm).
Remove the retaining clips from the right and left timing chain tensioners.
- Check for correct alignment of all timing marks.
- Remove the special tools from the camshafts.
- Install the crankshaft sensor ring on the crankshaft.
Lubricate the balance shaft journals with clean engine oil.
- Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
Position the balance shaft on the journals.
NOTEIt may be necessary to use an inspection mirror to see the marks.
- Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
Install the bearing caps in their original location. Install the bolts and tighten the bolts in the sequence shown to 89 inch lbs. (10 Nm).
WARNINGDo not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTEIf 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 this procedure can cause future oil leakage.
NOTEMake sure that the engine front cover gasket is in place on the engine front cover before installation.
- Apply silicone gasket and sealant along the cylinder head to cylinder block surface and the oil pan to cylinder block surface.
Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.
Tighten the engine front cover fasteners in sequence in two stages.
Stage 1: Tighten fasteners 1 through 7 to 20-30 Nm (15-22 ft. lbs.).
- Connect the CMP electrical connection.
- Install a new crankshaft front seal.
Raise and support the vehicle.
Loosely install the oil pan-to-front cover bolts, then tighten the bolts in the two stages, in the sequence shown.
Stage 1: Tighten to 20 Nm (15 ft. lbs.).
Connect the crankshaft position sensor electrical connector.
NOTEThe front lower hole in the power steering pump is not used.
- Position the power steering pump and install the bolts. Torque to 15-22 ft. lbs. (20-30 Nm).
- Install the drain plug.
- Lower the vehicle.
- Install the valve covers.
- Install the water pump.
- Install the radiator.
- Fill the engine with clean engine oil.
- Connect the battery ground cable.