Timing Components: Service and Repair
Timing Drive Components
Special Service tools
Removal
All vehicles
1. Remove the engine front cover.
2. Remove the spark plugs.
3. Remove the air deflector.
4. Disconnect the crankshaft position sensor electrical connector.
5. Remove the crankshaft position sensor.
6. CAUTION: Make sure the spark plugs are removed to enable the engine to rotate freely.
CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
Install the special tool 303-645.
Vehicles without supercharger
7. Remove the right-hand variable camshaft timing oil control unit housing.
^ Remove and discard the O-ring seals.
8. Remove the left-hand variable camshaft timing oil control unit housing.
^ Remove and discard the O-ring seals.
All vehicles
9. Install the special tool to the left-hand cylinder head.
10. Install the special tool to the Right-hand cylinder head.
11. Remove the primary timing chain tensioner assembly.
12. Remove the primary timing chain tensioner guide.
13. Remove the primary timing chain.
14. Remove the primary timing chain guide.
15. Remove the secondary timing chain tensioner retaining bolts.
16. Remove the camshaft sprockets.
^ Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
17. Remove the primary timing chain tensioner assembly.
18. Remove the primary timing chain tensioner guide.
19. Remove the primary timing chain.
20. Remove the crankshaft sprocket.
21. Remove the primary timing chain tensioner guide.
22. Remove the secondary timing chain tensioner retaining bolts.
23. Remove the camshaft sprockets.
^ Remove the secondary timing chain tensioner and secondary timing chain from the camshaft sprockets.
Installation
All vehicles
1. CAUTION: Do not tighten the camshaft sprocket retaining bolts.
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to rotate.
Install the camshaft sprockets.
^ Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
2. Install the secondary timing chain tensioner retaining bolts.
^ Tighten to 12 Nm.
3. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket.
^ Reposition the camshaft sprockets for the most advantageous position for use of the tool.
4. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.
5. Install the crankshaft sprocket.
6. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.
Install the primary timing chain.
^ Install the primary chain over the crankshaft sprocket and the intake sprocket.
7. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.
8. CAUTION: Use suitable protective covers on the vice jaws to protect the timing chain tensioner.
Secure the left-hand timing chain tensioner in the vice jaws.
9. CAUTION: During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
Using a suitable tool, hold the left-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
10. NOTE: The timing chain tensioner piston should retract with minimal force. If binding occurs, reposition the timing chain tensioner to eliminate side loading.
Slowly compress the left-hand timing chain tensioner.
11. NOTE: The retaining tool must remain in the timing chain tensioner until the timing chain tensioner is installed to the engine with the piston bottomed in the bore.
Using a suitable tool, retain the left-hand timing chain tensioner piston.
12. Install the primary timing chain tensioner assembly.
^ Tighten to 12 Nm.
13. Release the tension in the left-hand timing chain tensioner.
^ Remove the retaining tool.
14. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side.
^ Tighten to 120 Nm.
15. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction.
^ Tighten to 120 Nm.
16. CAUTION: Do not tighten the camshaft sprocket retaining bolts.
CAUTION: Make sure the secondary timing chain and camshaft sprockets are free to rotate.
Install the camshaft sprockets.
^ Install the secondary timing chain tensioner and secondary timing chain to the camshaft sprockets.
17. Install the secondary timing chain tensioner retaining bolts.
^ Tighten to 12 Nm.
18. Install the timing chain tensioning tool 303-532 to the exhaust camshaft sprocket.
^ Reposition the camshaft sprockets for the most advantageous position for use of the tool.
19. Install the primary timing chain guide.
^ Tighten to 12 Nm.
20. CAUTION: Make sure the timing chain slack is on the tensioned side of the timing chain.
Install the primary timing chain.
^ Install the primary chain over the crankshaft sprocket and the intake sprocket.
21. Install the primary timing chain tensioner guide.
^ Tighten to 12 Nm.
22. CAUTION: Use suitable protective covers on the vice jaws to protect the timing chain tensioner.
Secure the right-hand timing chain tensioner in the vice jaws.
23. CAUTION: During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
Using a suitable tool, hold the right-hand timing chain tensioner ratchet lock mechanism away from the ratchet stem.
24. NOTE: The timing chain tensioner piston should retract with minimal force. If binding occurs, reposition the timing chain tensioner to eliminate side loading.
Slowly compress the right-hand timing chain tensioner.
25. NOTE: The retaining tool must remain in the timing chain tensioner until the timing chain tensioner is installed to the engine with the piston bottomed in the bore.
Using a suitable tool, retain the right-hand timing chain tensioner piston.
26. Install the primary timing chain tensioner assembly.
^ Tighten to 12 Nm.
27. Release the tension in the right-hand timing chain tensioner.
^ Remove the retaining tool.
28. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction to tension the primary timing chain on its drive side.
^ Tighten to 120 Nm.
29. CAUTION: While applying the opposing force to sprocket and chain, tighten the sprocket bolt.
Using the special tool apply force to the tool in an anti-clockwise direction.
^ Tighten to 120 Nm.
30. Remove the special tool to the Right-hand cylinder head.
31. Remove the special tool to the left-hand cylinder head.
Vehicles without supercharger
32. Install the left-hand variable camshaft timing oil control unit housing.
^ Install new O-ring seals.
^ Tighten to 22 Nm.
33. Install the right-hand variable camshaft timing oil control unit housing.
^ Install new O-ring seals.
^ Tighten to 22 Nm.
All vehicles
34. Remove the special tool.
35. Install the crankshaft position sensor.
36. Connect the crankshaft position sensor electrical connector.
37. Install the air deflector.
38. Install the spark plugs.
39. Install the engine front cover.