Volkswagen Cars 2000-05

Crankshaft Damper (Balancer) 1

Print

Removal & Installation





Click image to see an enlarged view

Fig. Hex keys may be required to remove the damper bolts



Click image to see an enlarged view

Fig. Once loose, pull the bolts from the damper



Click image to see an enlarged view

Fig. Remove the damper by sliding it off the crankshaft

  1. Remove the negative battery cable.
  2.  
  3. Detach the wheel well splash shield if it interferes with damper removal.
  4.  
  5. Remove any engine accessory drive belts that are driven by the damper
  6.  
  7. Remove the crankshaft damper bolt(s).
  8.  
  9. Remove the crankshaft damper.
  10.  

To install:

  1. Installation is the reverse of removal.
  2.  

1.8L (Aeb/Atw/Awm/Awv) Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components to gain access to the front of the engine.
  4.  
  5. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator serpentine drive belt and release the tensioner.
    NOTE
    If necessary to lock the alternator tensioner in position, align the housing holes and insert an Allen wrench into the holes to secure its movement.

  6.  
  7. Using a 5 x 60mm bolt, secure the viscous fan pulley. Using a hex wrench, remove the viscous fan-to-pulley bolts. Remove the viscous fan assembly.
  8.  
  9. Remove the upper timing belt cover.
    NOTE
    If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  10.  
  11. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  12.  
  13. Remove the damper pulley-to-crankshaft bolts and the damper.

    Click image to see an enlarged view

    Fig. Crankshaft pulley and camshaft sprocket alignment locations-Volkswagen 1.8L (AEB/ATW/AWM/AWP/AWV/AWW) 4-Cyl engine

  14.  

To install:

  1. Install the damper to the crankshaft.
  2.  
  3. Using the center bolt, rotate the crankshaft 2 rotations in the direction of engine rotation until the camshaft and crankshaft marks align with their respective reference points.
  4.  
  5. Install the upper timing belt cover.
  6.  
  7. Install the drive belts.
  8.  
  9. Replace the remaining components by reversing the removal procedures.
  10.  
  11. Install the negative battery cable last.
  12.  
  13. Test drive the vehicle.
  14.  

1.8L (Awp/Aww/Bkf) Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover and splash shield.
  4.  
  5. Remove the right side headlight assembly.
  6.  
  7. Remove the intake pipe between the turbocharger and the charge air cooler.
  8.  
  9. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator serpentine drive belt and release the tensioner.
    NOTE
    If necessary to lock the alternator tensioner in position, align the housing holes and insert an Allen wrench into the holes to secure its movement.

  10.  
  11. Using the center bolt, rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
  12.  
  13. Remove the upper timing belt cover.
    NOTE
    If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  14.  
  15. Use an engine hoist and take the weight off the engine.
  16.  
  17. Remove the engine mount and body mount bolts and remove the engine mount from the cylinder block.

    Click image to see an enlarged view

    Fig. Removing engine and bolt mounts bolts-1.8L (AWP/AWW) 4-Cyl engine

  18.  
  19. Remove the damper pulley-to-crankshaft bolts and the damper.
  20.  

To install:

  1. Install the crankshaft pulley and bolts and tighten to 18 ft. lbs. (25 Nm).
  2.  
  3. Install the center timing belt cover and tighten the bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Install the upper timing belt cover.
  6.  
  7. Install the drive belts.
  8.  
  9. Replace the remaining components by reversing the removal procedures.
  10.  
  11. Install the negative battery cable last.
  12.  
  13. Test drive the vehicle.
  14.  

1.9L Alh Engines

Some special tools are required to perform this procedure properly. A camshaft locking bar, VW tool 3418 is used to secure the camshaft in position. A pin, VW tool 3359 is used to fix the injection pump position while the timing belt is removed. Camshaft sprocket holding tool 3036 is used to lock the camshaft sprocket. Puller T40001 is needed to remove the camshaft sprocket.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover and splash shield.
  4.  
  5. Place an open-end wrench on the alternator belt tensioner and rotate it clockwise toward the alternator to release the belt-s tension. Remove the alternator drive belt and release the tensioner.
  6.  
  7. Remove the brake booster vacuum pump.
  8.  
  9. Remove the upper timing belt cover.
  10.  
  11. Remove the valve cover.
  12.  
  13. Remove the tube between the intake pipe and the charge air cooler.
  14.  
  15. Rotate the crankshaft in the direction of engine rotation to position the No. 1 cylinder at Top Dead Center (TDC) of its compression stroke.
    NOTE
    If reusing the timing belt, mark its rotational direction so it may be installed in its original position.

  16.  
  17. Install camshaft locking bar onto the camshaft and cylinder head so it is equally balanced between both legs of the tool.
  18.  
  19. Lock the injection pump in place using pin 3359.
  20.  
  21. Loosen the injection pump sprocket bolts in a diagonal sequence.
    NOTE
    DO NOT loosen the pump sprocket hub bolt or the injection pump basic setting will be altered and cannot be reset with normal shop equipment.

  22.  
  23. Use an engine hoist and take the weight off the engine.
  24.  
  25. Remove the coolant reservoir tank and the power steering fluid reservoir and wire aside without disconnect the fluid lines.
  26.  
  27. Remove the engine mount and body mount bolts on the right side and remove the engine mount from the cylinder block.
  28.  
  29. Remove the left side engine mount bracket.
  30.  
  31. Remove the damper pulley-to-crankshaft bolts and the damper.
  32.  

To install:

  1. Install the crankshaft damper and tighten the bolts to 89 inch lbs. (10 Nm), plus an additional 90°.
  2.  
  3. Install the engine mount and body mount bolts to the cylinder block and tighten to 33 ft. lbs. (45 Nm).
  4.  
  5. The remainder of the installation is the reverse of the removal procedure.
  6.  

1.9L Engines-Except Alh Engines

Some special tools are required to perform this procedure properly. A flat bar, VW tool 2065A is used to secure the camshaft in position. A pin, VW tool 2064 is used to fix the pump position while the timing belt is removed. The camshaft and pump work against spring pressure and will move out of position when the timing belt is removed. It is not difficult to find substitutes but do not remove the timing belt without these tools.


WARNING
Do not turn the engine or camshaft with the timing belt removed. The pistons will contact the valves and cause internal engine damage.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the accessory drive belts.
  4.  
  5. Remove the crankshaft pulley.
  6.  
  7. Installation is the reverse of the removal procedure.
  8.  

2.0L (Aba) Engine

NOTE
Do not turn the engine or camshaft with the camshaft drive belt removed. The pistons will contact the valves and cause internal engine damage.

  1. Disconnect the negative battery cable and remove the accessory drive belts, crankshaft pulley and the timing belt cover(s).
  2.  
  3. Temporarily reinstall the crankshaft pulley bolt, if removed, and turn the crankshaft to Top Dead Center (TDC) of No. 1 piston. The mark on the camshaft sprocket should be aligned with the mark on the inner drive belt cover, if equipped, or the edge of the cylinder head.
  4.  
  5. On 8-valve engines, the notch on the crankshaft pulley should align with the dot on the intermediate shaft sprocket. With the distributor cap removed, the rotor should be pointing toward the No. 1 mark on the rim of the distributor housing.
  6.  
  7. Loosen the locknut on the tensioner pulley and turn the tensioner counterclockwise to relieve the tension on the timing belt.
  8.  
  9. Slide the timing belt off the sprockets.
  10.  

To install:

Click image to see an enlarged view

Fig. Camshaft timing belt sprocket TDC alignment mark-Volkswagen 2.0L (ABA) engines



Click image to see an enlarged view

Fig. Align the flywheel (A) or driveplate (B) as shown for TDC alignment for cylinder No. 1-Volkswagen 2.0L (ABA) engines



Click image to see an enlarged view

Fig. When the No. 1 cylinder is at TDC, the ignition rotor should face the notch in the distributor housing-Volkswagen 2.0L (ABA) engine

  1. Install the new timing belt and tension the belt so that it can be twisted 90 degrees at the middle of its longest section, between the camshaft and intermediate sprockets.
  2.  
  3. Recheck the alignment of the timing marks, if correct, turn the engine 2 full revolutions to return to TDC of No. 1 piston. Recheck belt tension and timing marks. Readjust as required. Tighten the tensioner nut to 33 ft. lbs. (45 Nm).
  4.  
  5. Reinstall the belt cover and accessory drive belts.
    NOTE
    When running the engine, there will be a growling noise that rises and falls with engine speed if the belt is too tight.

  6.  

2.0L (Aeg/Avh/Azg/Bdc/Bev/Bgd) 4-Cylinder Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components to gain access to the front of the engine.
  4.  
  5. Remove the serpentine drive belt by performing the following procedure:
    1. Using an open-end wrench, rotate the serpentine drive belt tensioner clockwise to relieve the belt tension. Using tool 3090 or a drift awl, lock the tensioner in place.
    2.  
    3. Remove the serpentine drive belt.
    4.  

  6.  
  7. Remove the drive tensioner from the engine.
  8.  
  9. Rotate the crankshaft to position the No. 1 cylinder on Top Dead Center (TDC) of its compression stroke.
  10.  
  11. Remove the upper timing belt cover.
    NOTE
    If the camshaft sprocket is not aligned with its timing mark, rotate the crankshaft 1 complete turn until the crankshaft and camshaft timing marks align.

  12.  
  13. Install the Engine Support tool 10-222A with Leg tools and support the weight of the engine.
  14.  
  15. From the front of the engine, remove the engine mount and bracket which will interfere with the timing belt removal.
  16.  
  17. Mark the rotational direction of the timing belt for reinstallation purposes.
  18.  
  19. Remove the vibration damper-to-crankshaft sprocket bolts and the damper.
  20.  
  21. Remove the center and lower timing belt covers.
  22.  
  23. Release the timing belt tensioner and remove the timing belt.

    Click image to see an enlarged view

    Fig. View of crankshaft damper aligned with the timing mark-Volkswagen 2.0L (AEG/AVH/AZG/BDC) 4-Cyl. Engine



    Click image to see an enlarged view

    Fig. View of camshaft damper aligned with the timing mark-Volkswagen 2.0L (AEG/AVH/AZG/BDC) 4-Cyl. Engine



    Click image to see an enlarged view

    Fig. Adjusting the timing belt tensioner-Volkswagen 2.0L (AEG/AVH/AZG/BDC) 4-Cyl. engine

  24.  

To install:

  1. Make sure that the camshaft and crankshaft timing marks are aligned.
  2.  
  3. Install the timing belt, with the arrow pointing in the direction of rotation, on the crankshaft sprocket, the water pump sprocket and the camshaft sprocket.
  4.  
  5. Install the lower and center timing belt covers.
  6.  
  7. Install the vibration damper and torque the damper-to-crankshaft sprocket bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Using the 2-Hole Tensioning tool T-10020, rotate the timing belt tensioner counterclockwise until notch 1 and indicator 2 align. Then, tighten the timing belt tensioner nut to 15 ft. lbs. (20 Nm).
  10.  
  11. Rotate the crankshaft 2 complete revolutions and recheck the timing marks.
  12.  
  13. Install the upper timing belt cover.
  14.  
  15. Install the engine bracket and torque the bolts to 33 ft. lbs. (45 Nm).
  16.  
  17. Install the engine mount and torque the mount-to-bracket bolts to 30 ft. lbs. (40 Nm) plus 90 degree turn ( 1 / 4 turn), the mount-to-body bolts to 18 ft. lbs. (25 Nm) and the mount-to-engine bracket bolts to 44 ft. lbs. (60 Nm) plus 90 degree turn ( 1 / 4 turn).
  18.  
  19. Install the timing belt tensioner and torque the bolts to 18 ft. lbs. (25 Nm).
  20.  
  21. Complete the installation by reversing the removal procedures.
  22.  
  23. Test drive the vehicle.
  24.  

2.8L (Atq) Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the necessary components to gain access to the front of the engine.
  4.  
  5. Remove the serpentine drive belt by performing the following procedure:
    1. Using Spanner Wrench No. 3212, secure the viscous fan pulley. Using an Open-end Spanner Wrench 3212, remove the viscous fan bearing housing by turning it clockwise.
      NOTE
      The viscous fan is mounted with a left-handed thread; turn it clockwise to loosen it.

    2.  
    3. Place a 17mm box wrench on the serpentine drive belt tensioner and turn the tensioner clockwise until the 2 holes align; insert drift 3204 into the holes to secure the tensioner in place.
    4.  
    5. Mark the running direction of the serpentine drive belt and remove it from the pulleys.
    6.  

  6.  
  7. Rotate the crankshaft by hand to align the crankshaft pulley mark with the arrow on the engine housing and the large hole in each camshaft sprocket must face inward and must align; this should be Top Dead Center (TDC) of the No. 1 cylinder-s compression stroke. If these conditions are not correct, rotate the crankshaft one complete revolution and realign.
  8.  
  9. On the left side of the cylinder block near the crankshaft, remove the sealing plug.
  10.  
  11. Insert Crankshaft Holder tool No. 3242 into the sealing plug hole to secure the crankshaft.
  12.  
  13. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, insert a 2mm spring pin through the tensioner housing and tensioner plunger to secure it in place. When the plunger is secure, release the wrench tension.
  14.  
  15. Remove the dampener-to-crankshaft bolts and the damper.
    NOTE
    It is not necessary to remove the center bolt when removing the crankshaft damper.

  16.  
  17. Remove the serpentine belt idler and the crankshaft damper guard.
  18.  
  19. Mark the running direction of the timing belt and remove it from the pulleys.

    Click image to see an enlarged view

    Fig. Crankshaft pulley alignment location for TDC-Volkswagen 2.8L (ATQ) V6 engine



    Click image to see an enlarged view

    Fig. Left camshaft sprocket alignment position for TDC; right camshaft position is similar-Volkswagen 2.8L (ATQ) V6 engine



    Click image to see an enlarged view

    Fig. View of crankshaft holding tool installed-Volkswagen 2.8L (ATQ) V6 engine



    Click image to see an enlarged view

    Fig. View of camshaft locator bar installed-Volkswagen 2.8L (ATQ) V6 engine

  20.  

To install:

  1. Make sure that the camshaft pulleys and the crankshaft pulley are in alignment with TDC of the No. 1 cylinder-s compression stroke.
  2.  
  3. Install the timing belt; make sure the timing belt is installed in the correct running direction from which it was removed.
  4.  
  5. Using a 8mm Allen® wrench, rotate the timing belt tensioner roller clockwise until the tensioner is compressed; then, remove the 2mm spring pin from the tensioner housing. Slowly, release the tensioner-s spring pressure to put pressure on the timing belt.
  6.  
  7. Install the crankshaft damper guard and the serpentine belt idler pulley; torque the idler pulley bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Install the crankshaft damper and torque the damper-to-crankshaft bolts to 15 ft. lbs. If the damper-to-crankshaft center bolt was removed, torque it to 147 ft. lbs. (200 Nm) plus 180° ( 1 / 2 turn).
  10.  
  11. Remove the Crankshaft Holder tool No. 3242 and install the sealing plug.
  12.  
  13. Replace the remaining components by reversing the removal procedures.
  14.  
  15. Refill the cooling system and the automatic transaxle. Connect the electrical connectors. Install the negative battery cable last.
  16.  
  17. Test drive the vehicle.
  18.  

2.8L (Bdf) Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove engine covers at the front of the engine compartment and underneath the vehicle.
  6.  
  7. Mark the rotation direction of the drive belt.
  8.  
  9. Insert an M8x50 bolt into the threaded hole of the belt tensioner roller and tighten just enough until tension is off belt and drive belt can be removed.
  10.  
  11. Remove the cylinder head cover.
  12.  
  13. Remove the necessary components to gain access to the front of the engine.
  14.  
  15. Place the crankshaft at TDC for no. 1 cylinder.
  16.  
  17. Mark the camshaft timing chain rotation direction with a paint mark.
  18.  
  19. Remove the camshaft roller chain tensioner.
  20.  
  21. Remove the 8 mounting bolts and remove the chain front cover
  22.  
  23. Disconnect the front exhaust pipe from the exhaust manifold.
  24.  
  25. Check that timing is at TDC by looking down between timing chain sprockets of the intermediate shaft. A groove should be visible between the chain edges.
    NOTE
    If the groove cannot be seen, turn crankshaft one more revolution until groove can be seen.

  26.  
  27. Insert camshaft gauge T10068 into both camshaft grooves.
    NOTE
    If the gauge cannot be inserted, rotate crankshaft about .20 inches (5 mm) above TDC position until gauge can be inserted.


    NOTE
    Markings -A- and -B- on the camshaft adjusters must match the notches of control housing -C.-

  28.  
  29. Remove the camshaft adjusters together with the timing chain from the camshafts.
  30.  
  31. Remove the two bolts from the glide track located at lower left below camshaft sprocket.
  32.  
  33. Remove the timing chain from the camshaft adjusters and place chain on its side.

    Click image to see an enlarged view

    Fig. Lining up camshaft adjusters to remove timing chain-2.8L (BDF) engine



    Click image to see an enlarged view

    Fig. Identifying TDC position on timing chain sprockets of intermediate shaft-2.8L (BDF) engine



    Click image to see an enlarged view

    Fig. Identifying timing chain positioning on crankshaft and intermediate shaft sprockets-2.8L (BDF) engine

  34.  

To install:

  1. Adjust the milled tooth of the drive pinion to line up with the bearing separating gap at TDC on cylinder no. 1.
  2.  
  3. Install the glide track bolts, without the collar, and torque to 89 inch lbs. (10 Nm).
  4.  
  5. Install the timing chains and the intermediate shaft gears (if removed), ensuring that the timing chain rotation direction is correct.
  6.  
  7. Check that the marking on the gear matches with the notches on the intermediate shaft thrust washer.
  8.  
  9. Hand tighten the intermediate shaft gear bolts.
  10.  
  11. Use a small screwdriver to release the tension of the locking splines in the chain tensioner and press the tensioner track against the tensioner.
  12.  
  13. Install the timing chain tensioner bolts and torque to 72 inch lbs. (8 Nm).
  14.  
  15. Use a socket wrench to hold the crankshaft damper in position.
  16.  
  17. With the intermediate shaft sprockets lined up correctly, torque the bolts to 44 ft. lbs. (60 Nm), plus 90°.
  18.  
  19. Check that all sprockets are correctly lined up and cylinder no. 1 is at TDC.
  20.  
  21. Insert camshaft adjusting ruler tool T10068 into camshaft grooves.
  22.  
  23. Guide the timing chain between the tensioning track and the glide track.
  24.  
  25. Install the intake camshaft adjuster first with the timing chain installed, then install the exhaust camshaft adjuster.
    NOTE
    Exhaust camshaft adjuster can be offset in two directions. When installing, make sure the camshaft position sensor is turned to stop in a clockwise direction. Distance between the milled teeth markings on the timing chain at the camshaft adjuster markings is exactly 16 rollers on the timing chain.


    NOTE
    Markings -A- and -B- on the camshaft adjusters must match the notches of control housing -C.-

  26.  
  27. Hand tighten NEW bolts for camshaft adjusters.
  28.  
  29. Remove camshaft adjusting ruler T10068.
  30.  
  31. Rotate crankshaft 2 revolutions and recheck valve timing.
  32.  
  33. If valve timing is okay, secure camshafts in position and torque camshaft adjuster bolts to 44 ft. lbs. (60 Nm), plus 90°.
  34.  
  35. Place oil on the front cover O ring and install in cover.
  36.  
  37. Coat the front cover sealing surface with sealant and hand tighten the bolts.
  38.  
  39. Torque the front cover M6 bolts to 72 inch lbs. (8 Nm), and tighten the M8 bolts to 18 ft. lbs. (25 Nm).
  40.  
  41. Install the camshaft roller chain tensioner and torque the bolts to 30 ft. lbs. (40 Nm).
  42.  
  43. Rotate crankshaft 2 revolutions and recheck valve timing.
  44.  
  45. Replace the remaining components by reversing the removal procedures.
  46.  
  47. Reconnect the negative battery cable.
  48.  
  49. Test drive the vehicle.
  50.  

4.0L (Bdp) Engines

NOTE
The following procedure is for cylinder bank no. 1. Cylinder bank no. 2 is similar.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine top cover.
  6.  
  7. Remove the engine insulation cover.
  8.  
  9. Drain the engine coolant into an approved container.
  10.  
  11. Disconnect the coolant hoses at the radiator.
  12.  
  13. Remove or disconnect:

    Upper intake manifold.
     

  14.  
  15. Disconnect the connectors to the ignition coils with power output stage and move the wiring harness clear.
  16.  
  17. Remove the ignition coils using T10094 extractor.
  18.  
  19. Remove or disconnect:
    NOTE
    Cover intake ports to prevent debris from entering.



    Cylinder head cover
     
    Fuel rail with injectors.
     
    Lower intake manifold spacer.
     



    Coolant pipes.
     
    Intake pipes.
     

  20.  
  21. Turn the crankshaft until no. 1 cylinder is at TDC. Mark on crankshaft damper must align with mark on cylinder block joint.
  22.  
  23. Remove the camshaft chain tensioner.
  24.  
  25. Remove the timing chain upper cover.
  26.  
  27. Remove the timing chain lower cover.
  28.  
  29. Mark the timing chain rotation direction for installation.
  30.  
  31. Remove the exhaust camshaft adjuster bolts.
  32.  
  33. Remove the intake camshaft adjuster bolts.
  34.  
  35. Remove the camshaft adjusters together with the timing chain.
  36.  
  37. Remove the timing chain guide rail.

    Click image to see an enlarged view

    Fig. Locating TDC alignment marks-4.0L engine

  38.  

To install:

  1. Set the crankshaft and camshafts to TDC for cylinder No. 1.
  2.  
  3. Secure the crankshaft from turning.
  4.  
  5. Install camshaft adjuster guide T10068 into horizontal slots on camshafts to lock them in place
  6.  
  7. On cylinder bank no. 1, install the timing chain as follows:
  8.  
  9. On the intake camshaft adjuster, turn the Hall sensor wheel clockwise to its stop.
  10.  
  11. On the exhaust camshaft adjuster, turn the Hall sensor wheel counterclockwise to its stop.
  12.  
  13. Install the timing chain and camshaft adjuster as a unit.
  14.  
  15. Copper link -A- of timing chain must be positioned on the top of the intermediate shaft.
  16.  
  17. Copper link of timing chain must align with -B1- arrow on intake camshaft adjuster
  18.  
  19. Copper link of timing chain must align with -B1- arrow on exhaust camshaft adjuster
  20.  
  21. Tighten NEW camshaft adjuster bolts hand tight.
  22.  
  23. Install the guide rail and tensioning rail.
  24.  
  25. On cylinder bank no. 2, install the timing chain as follows:
  26.  
  27. On the intake camshaft adjuster, turn the Hall sensor wheel clockwise to its stop.
  28.  
  29. On the exhaust camshaft adjuster, turn the Hall sensor wheel counterclockwise to its stop.
  30.  
  31. Install the timing chain and camshaft adjusters as a unit.
  32.  
  33. Copper link -A- of timing chain must be positioned on the top of the intermediate shaft.
  34.  
  35. Copper link of timing chain must align with -B2- arrow on intake camshaft adjuster
  36.  
  37. Copper link of timing chain must align with -B2- arrow on exhaust camshaft adjuster
  38.  
  39. Tighten NEW camshaft adjuster bolts hand tight.
  40.  
  41. Install the guide rail and tensioning rail.
  42.  
  43. Install the chain tensioner limit stop and tighten to 15 ft. lbs. (20 Nm).
  44.  
  45. Install the chain tensioner and tighten to 71 inch lbs. (10 Nm).
  46.  
  47. On both cylinder banks, proceed as follows:
  48.  
  49. Remove camshaft adjuster guide T10068 from both heads.
  50.  
  51. Hold crankshaft from turning and install NEW intermediate sprocket bolt and tighten to 44 ft. lbs. (60 Nm).
  52.  
  53. Hold camshafts in place with a 32 mm open end wrench, and tighten NEW camshaft adjuster bolts to 44 ft. lbs. (60 Nm).
  54.  
  55. Install lower timing chain cover and tighten bolts in sequence.
  56.  
  57. Install sealant to cylinder bank no. 1 upper timing belt cover and tighten bolts in sequence to 71 inch lbs. (10 Nm).
  58.  
  59. Install sealant to cylinder bank no. 2 upper timing belt cover and tighten bolts in sequence to 71 inch lbs. (10 Nm).
  60.  
  61. Replace the remaining components by reversing the removal procedures.
  62.  
  63. Reconnect the negative battery cable.
  64.  
  65. Test drive the vehicle.

    Click image to see an enlarged view

    Fig. Installing timing chain on cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on intake camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on exhaust camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Installing timing chain on cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on intake camshaft adjuster for cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Locating copper timing chain link with arrow on exhaust camshaft adjuster for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for upper timing chain cover for cylinder bank no. 1-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for upper timing chain cover for cylinder bank no. 2-4.0L engine



    Click image to see an enlarged view

    Fig. Tightening sequence for lower timing chain cover-4.0L engine

  66.  

 
label.common.footer.alt.autozoneLogo