Timing Components: Service and Repair

Timing Drive Components (12.65.13)

Removal

1. Remove the engine front cover.
2. Remove the spark plugs.

3. NOTE: Note the position of the crankshaft position (CKP) sensor pulse wheel during removal. It must be returned to its original position during installation.

Remove the crankshaft position (CKP) sensor pulse wheel.





4. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

Install the crankshaft pulley retaining bolt and washer.





5. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

Rotate the crankshaft clockwise until the crankshaft keyway is at the 7 O'clock position, the alignment mark on the right-hand intake camshaft sprocket is at the 1 O'clock position and the alignment mark on the right-hand exhaust camshaft sprocket is at the 8 O'clock position.





6. Release the timing chain tensioner ratchet.





7. NOTE: Keep the timing chain tensioner ratchet released.

Reposition the timing chain tensioner plunger.





8. Retain the timing chain tensioner plunger.





9. Remove the right-hand timing chain tensioner.





10. Remove the right-hand timing chain outer guide.





11. Remove the right-hand timing chain.





12. CAUTION: Inspect and replace the O-ring seal if necessary.

Remove the right-hand timing chain inner guide.





13. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

Rotate the crankshaft clockwise until the crankshaft keyway is at the 11 O'clock position, the alignment mark on the lefthand intake camshaft sprocket is at the 9 O'clock position and the alignment mark on the left-hand exhaust camshaft sprocket is at the 2 O'clock position.





14. NOTE: Right-hand bank shown, left-hand bank similar.

Release the timing chain tensioner ratchet.





15. NOTE: Right-hand bank shown, left-hand bank similar.

NOTE: Keep the timing chain tensioner ratchet released.

Reposition the timing chain tensioner plunger.





16. NOTE: Right-hand bank shown, left-hand bank similar.

Retain the timing chain tensioner plunger.





17. Remove the left-hand timing chain tensioner.





18. Remove the left-hand timing chain inner guide.





19. Remove the left-hand timing chain.





20. CAUTION: Inspect and replace the O-ring seal if necessary.

Remove the left-hand timing chain outer guide.





21. CAUTION: Make sure the crankshaft keyway is at the 9 O'clock position before any further engine repairs are carried out.

Remove the crankshaft pulley retaining bolt and washer.





22. Remove the crankshaft sprocket.





Installation

1. NOTE: Make sure the crankshaft sprocket timing marks are facing outwards.

Install the crankshaft sprocket.





2. CAUTION: Make sure the crankshaft keyway is at the 9 O'clock position before the camshaft positions are aligned.

Install the crankshaft pulley retaining bolt and washer.





3. Rotate the left-hand intake camshaft clockwise until the camshaft sprocket alignment mark is at the 9 O'clock position and rotate the left-hand exhaust camshaft sprocket clockwise until the camshaft sprocket alignment mark is at the 2 O'clock position.





4. Rotate the right-hand intake camshaft clockwise until the camshaft sprocket alignment mark is at the 5 O'clock position and rotate the right-hand exhaust camshaft sprocket clockwise until the camshaft sprocket alignment mark is at the 12 O'clock position.





5. Rotate the crankshaft clockwise until the keyway is at the 11 O'clock position.

6. CAUTION: Inspect and replace the O-ring seal if necessary.

CAUTION: Make sure the O-ring seal is correctly installed.

Install the left-hand timing chain outer guide.
- Tighten the retaining bolts in the sequence shown in two stages.
- Stage 1: Tighten bolt 1 to 25 Nm.
- Stage 2: Tighten bolts 2 to 25 Nm.





7. CAUTION: Make sure the crankshaft keyway is at the 11 O'clock position, the alignment mark on the left-hand intake camshaft sprocket is at the 9 O'clock position and the alignment mark on the left-hand exhaust camshaft sprocket is at the 2 O'clock position.

8. CAUTION: Make sure the timing chain alignment marks are correctly positioned to the crankshaft sprocket and camshaft sprocket alignment marks.

9. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.

Install the left-hand timing chain.





8. Install the left-hand timing chain inner guide.





9. CAUTION: Do not manually adjust the timing chain tensioner.

Install the left-hand timing chain tensioner.
- Tighten to 25 Nm.





10. CAUTION: Do not manually adjust the timing chain tensioner.

Make sure the left-hand timing chain alignment marks have remained correctly positioned to the camshaft sprocket and crankshaft sprocket alignment marks.





11. CAUTION: Do not manually adjust the timing chain tensioner.

Remove the timing chain tensioner retaining pin.





12. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

Rotate the crankshaft clockwise until the crankshaft keyway is at the 3 O'clock position.





13. CAUTION: Inspect and replace the O-ring seal if necessary.

CAUTION: Make sure the O-ring seal is correctly installed.

Install the right-hand timing chain inner guide.
- Tighten the retaining bolts in the sequence shown in two stages.
- Stage 1: Tighten bolt 1 to 25 Nm.
- Stage 2: Tighten bolts 2 to 25 Nm.





14. CAUTION: Make sure the crankshaft keyway is at the 3 O'clock position, the alignment mark on the right-hand intake camshaft sprocket is at the 5 O'clock position and the alignment mark on the right-hand exhaust camshaft sprocket is at the 12 O'clock position.

CAUTION: Make sure the timing chain alignment marks are correctly positioned to the crankshaft sprocket and camshaft sprocket alignment marks.

CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.

Install the right-hand timing chain.





15. Install the right-hand timing chain outer guide.





16. CAUTION: Do not manually adjust the timing chain tensioner.

Install the right-hand timing chain tensioner.
- Tighten to 25 Nm.





17. CAUTION: Do not manually adjust the timing chain tensioner.

Remove the timing chain tensioner retaining pin.





18. CAUTION: Make sure the right-hand timing chain alignment marks have remained correctly positioned to the camshaft sprocket and crankshaft sprocket alignment marks.

CAUTION: Do not manually adjust the timing chain tensioner.

Make sure all the timing chain alignment marks are in the positions shown.





19. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

NOTE: Rotate the crankshaft using hand tools only.

Rotate the crankshaft two complete turns clockwise to make sure the valves and pistons do not clash.

20. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

Remove the crankshaft pulley retaining bolt and washer.





21. CAUTION: Make sure the CKP sensor pulse wheel is correctly installed with the missing tooth aligned to the crankshaft keyway.

CAUTION: Make sure the CKP sensor pulse wheel is correctly installed with the teeth pointing outwards.

Install the CKP sensor pulse wheel.





22. Install the spark plugs.
- Tighten to 15 Nm.

23. Install the engine front cover.