Timing Chain: Service and Repair
REMOVAL1. Relieve fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL PRESSURE RELEASE.
2. Remove engine undercovers.
3. Remove right front wheel and engine side cover.
4. Drain coolant, then remove radiator.
5. Remove air duct to intake manifold.
6. Remove drive belts, water pump pulley, alternator, and power steering pump.
7. Disconnect or remove all hoses, linkages, electrical connectors and accessories necessary for timing belt removal.
8. Remove spark plugs, then disconnect air induction valve (A.I.V) and resonator.
9. Remove rocker cover and oil separator.
10. Remove intake manifolds supports, oil filter bracket, and power steering pump bracket.
Fig. 6 Timing Chain Removal:
11. Set No. 1 cylinder at TDC on its compression stroke. Rotate crankshaft until mating mark on camshaft sprocket is set at position as shown in Fig. 6.
12. Remove chain tensioner and distributor. Do not turn rotor with distributor removed.
13. Remove timing chain guide and camshaft sprockets.
14. Remove camshafts, camshafts brackets, oil tubes and baffle plate.
15. Disconnect water hoses for cylinder block and heater.
16. Remove starter motor.
17. Remove water pipe bolt and cylinder head outside attaching bolts.
Fig. 7 Cylinder Head Bolt Removal Sequence:
Fig. 8 Exploded View Of Timing Chain:
18. Remove cylinder head bolts in sequence shown, Fig 7. Bolts should be loosened in two or three steps.
19. Remove oil pan, refer to OIL PAN.
20. Remove crankshaft pulley, then set a suitable transmission jack under main bearing beam.
21. Remove front engine mounting.
22. Remove front cover, Fig. 8.
23. Remove timing chain guides and timing chain.
Fig. 9 Timing Chain Alignment:
INSTALLATION
1. Install crankshaft sprocket on crankshaft.
2. Position crankshaft so that the No. 1 piston is set at TDC, then fit timing chain to crankshaft sprocket so mating mark is line with mating mark on crankshaft sprocket, Fig. 9.
3. Install timing chain and guides.
4. Install oil pump drive spacer and front cover.
5. Install front engine mounting and crankshaft pulley.
6. Set No. 1 piston at TDC on its compression stroke.
7. Install oil strainer, baffle plate and oil pan.
Fig. 10 Cylinder Head Bolt Dimension:
8. Install cylinder head completely with intake and exhaust manifolds. Cylinder head bolts can be reused providing dimension A is not exceeded. Dimension A should be 6.2278 inch, Fig. 10.
Fig. 11 Cylinder Head Bolt Tightening Sequence:
9. Torque cylinder head bolts in sequence shown in Fig. 11, as follows:
a. Torque bolts to 22 ft. lbs.
b. Torque bolts to 58 ft. lbs.
c. Loosen bolts completely, then torque bolt to 25-33 ft. lbs.
d. Turn bolts 90-100° clockwise with tool or suitable angle wrench.
e. If angle wrench is not available, mark side of each cylinder head bolt with a paint mark facing front of engine, then turn all bolts 90-100° clockwise.
f. Ensure paint mark on each bolt faces rear of engine.
g. Do not turn any bolt 180-200° clockwise all at once.
10. Install cylinder head outside bolts.
11. Install water pipe bolt.
12. Install starter motor, then water hoses for the cylinder block and heater.
13. Install left camshaft end bracket, removing all traces of liquid gasket from mating surface.
Fig. 12 Camshaft Installation:
14. Install camshafts, camshaft brackets, oil tubes, and baffle plate. Position left camshaft key at about 12 o'clock and right camshaft key at about 10 o'clock, Fig. 12.
Fig. 13 Camshaft Bolt Tightening Sequence:
Fig. 14 Camshaft Bolts A, B, C & D Tightening Sequence:
15. Torque camshaft bolts as follows:
a. Torque righthand camshaft bolts Nos. 9, 10, 1 and 8 (in that order) to 1.4 ft. lbs., Fig. 13.
b. Torque lefthand camshaft bolts Nos. 11, 12, 1 and 10 (in that order) to 1.4 ft. lbs., Fig. 13.
c. Torque all bolts in numerical order to 4.3 ft. lbs.
d. Torque all A, B and C type bolts, Fig. 14, to 6.7-8.7 ft. lbs. and type D bolts to 13-19 ft. lbs.
Fig. 15 Camshaft Sprockets Installation:
16. Install camshaft sprockets. Line up mating marks on timing chain with mating marks on camshaft sprockets, Fig. 15.
Fig. 16 Locking Camshaft:
17. Lock camshafts as shown in Fig. 16. Torque to 101-116 ft. lbs.
18. Install timing chain guide.
Fig. 17 Camshaft Positioning:
Fig. 18 Distributor Rotor Head:
19. Install distributor, ensuring position of camshaft, Fig. 17. and rotor head is set as shown in, Fig. 18.
Fig. 19 Chain Tensioner Installation:
20. When installing chain tensioner, press cam stopper down and press in sleeve until hook can be engaged on pin. When tensioner is bolted in position the hook will release automatically. Ensure cam stopper faces front of engine, Fig. 19.
21. Install oil filter and power steering pump brackets.
22. Install intake manifold supports, rocker cover and oil separator.
Fig. 20 Rocker Cover Bolt Tightening Sequence:
23. Torque rocker cover as follows:
a. Torque rocker cover nuts Nos. 1, 10, 11, 13 and 8 (in that order) to 2.9 ft. lbs., Fig. 20.
b. Torque rocker cover nuts Nos. 1 to 13 as shown in Fig. 20. to 5.8-7.2 ft. lbs.
24. Install A.I.V and resonator.
25. Install spark plugs and leads.
26. Install all hoses, linkages, electrical connectors and accessories.
27. Install power steering pump, alternator, water pump pulley and drive belts.
28. Install air duct to intake manifold.
29. Install radiator, hoses and refill with coolant.
30. Install engine side cover and right front wheel.
31. Install engine undercovers.