Timing chain removal:
1. Disconnect negative battery cable. Drain cooling system. Remove windshield washer fluid reservoir. Rotate accessory drive belt tension-er clockwise (viewed from timing chain end of engine) to release tension from accessory drive belt. Remove accessory drive belt. Remove mounting bolts and generator.
2. Using spanner wrench in holes on front of power steering pump pulley, hold power steering pump pulley while removing power steering pump pulley nut. Remove power steering pump pulley from power steering pump. Remove bolts/nuts and power steering pump. Secure power steering pump aside.
3. Raise and support vehicle. Remove passenger's side front wheel and lower engine cover. Support oil pan with floor jack and wooden block. Remove right (timing chain side) engine mount insulator-to-engine mount bracket bolts/nuts. Remove right (timing chain side) engine mount insulator-to-body bolts.
4. Remove ignition coils from spark plugs. Disconnect spark plug wires from spark plugs. Disconnect necessary hoses and engine wiring cover for removal of valve cover. Remove valve cover bolts/nuts, seal washers, cable bracket, valve cover and gasket.
5. Rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder No. 1 is at TDC on compression stroke. Cylinder number one is the front cylinder at timing chain end of engine.
6. Ensure timing marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover. See Fig. 2. If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment.
7. Using Pulley Holder (SST 09213-70010) and Handle (SST 09330-00021), hold crankshaft pulley. Remove crankshaft pulley bolt. Using puller, remove crankshaft pulley.
8. Remove bolts and crankshaft position sensor. See Fig. 5. Remove bolts/nuts and accessory drive belt tension-er. Remove bolts and right (timing chain side) engine mount bracket from front of cylinder block.
9. Remove bolt and timing chain tension-er from side of timing chain cover. Note location of water pump bolts for installation reference. Remove bolts, water pump and "O" ring. See Fig. 5
10. Remove bolts/nuts, stud bolt and timing chain cover. Timing chain cover may be removed by prying between cylinder head and timing chain cover at the area just above water pump opening on timing chain cover.
11. Remove crank angle sensor plate, bolt and timing chain tension-er slipper. See Fig. 5.
12. Remove crankshaft sprocket with timing chain. If crankshaft sprocket cannot be removed by hand, place shop towels against front of cylinder block, just behind crankshaft sprocket. Using screwdrivers, pry crankshaft sprocket with timing chain from crankshaft. Remove bolts and timing chain vibration damper. See Fig. 5.
CAUTION:Use care not to damage valve lifter or cylinder head when
removing camshaft sprocket.
13. If necessary to remove camshaft sprockets, hold camshaft by placing wrench at hexagonal area near center of camshaft. DO NOT damage cylinder head or valve lifter. Remove bolt and camshaft sprocket from camshaft. If necessary to remove crankshaft front seal, use hammer and drift to remove seal from timing chain cover.
Installation
1. Use hammer and Seal Installer (SST 09309-37010) to install crankshaft front seal in timing chain cover (if removed). Install seal until seal surface is even with timing chain cover. Apply grease to lip of oil seal.
2. If installing camshaft sprocket, align groove in camshaft sprocket with pin in camshaft. Install camshaft sprocket on camshaft. Install and tighten camshaft sprocket bolt to specification.
3. Rotate camshafts by using hexagonal area on camshaft so timing marks on camshaft sprockets are aligned. See Fig. 2. Temporarily install crankshaft pulley bolt in crankshaft.
4. Using crankshaft pulley bolt, rotate crankshaft clockwise so key in crankshaft is positioned at 12 o'clock. Remove crankshaft pulley bolt. Install timing chain vibration damper. Tighten bolt to specification.
5. Install timing chain on crankshaft sprocket so No. 1 marked link on timing chain aligns with timing mark on crankshaft sprocket. Perform STEP 1 in illustration. See Fig. 29. Ensure timing mark on crankshaft sprocket is pointing toward front of engine. It may be necessary to use hammer and Seal/Sprocket Installer (SST 09223-22010) to tap crankshaft sprocket onto crankshaft.
6. Install timing chain on camshaft so No. 53 and 67 marked links align with timing marks with the 2 dots on camshaft sprockets. Perform STEP 2 in illustration. See Fig. 29. Ensure tension exists on timing chain between crankshaft sprocket and camshaft sprocket on intake camshaft.
7. Install timing chain tension-er slipper between intake camshaft sprocket and crankshaft sprocket so that slipper engages with cylinder head stopper. Perform STEP 3 in illustration. See Fig. 29. DO NOT rotate crankshaft when installing timing chain tension-er slipper. Install and tighten timing chain tension-er slipper bolt to specification
8. Install crank angle sensor plate on crankshaft so that "F" mark is facing toward timing chain end of engine. Perform STEP 4 in illustration. See Fig. 29.
9. Ensure sealing surfaces on rear of timing chain cover and front of cylinder block and cylinder head are clean. Apply sealant on rear of timing chain cover and front of cylinder block and cylinder head at specified areas. See Fig. 30 or Fig. 31.
CAUTION: When installing timing chain cover, use care not to allow timing chain and timing chain tension-er slipper to contact sealant surfaces on timing chain cover. After installing timing chain cover and water pump, the accessory drive belt tension-er and right (timing chain side) engine mount bracket must be installed within fifteen minutes.
10. Install new "O" ring on water pump. Install timing chain cover, water pump and bolts/nuts. Ensure proper length bolts and stud bolt are installed in proper area when installing timing chain cover and water pump. See Fig. 51 or Fig. 53. Tighten bolts/nuts and stud bolt to specification.
11. Install right (timing chain side) engine mount bracket. Apply thread sealant to center of the threads on bolts for right (timing chain side) engine mount bracket. Do not apply sealant on the last three threads of these bolts. Install and tighten bolts to specification.
12. Install accessory drive belt tension-er. Tighten bolts/nuts to specification. Using wrench, rotate accessory drive belt tension-er three times the full length of its travel.
13. Install crankshaft position sensor. Tighten bolt to specification. Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification while holding crankshaft pulley with pulley holder.
14. Depress pawl on timing chain tension-er downward while pushing the plunger fully inward and then engage the hook with the pin on plunger to hold plunger in retracted position. Perform STEP 1 in illustration. See Fig. 28.
15. Install timing chain tension-er by hand until "O" ring on timing chain tension-er contacts the chamfered position and then install bolts. Gradually tighten bolts to move timing chain tension-er inward to fully installed position. Tighten bolt to specification.
15. Using crankshaft pulley bolt, rotate crankshaft counterclockwise (viewed from timing chain end of engine) and disengage hook from pin on plunger of timing chain tension-er. Rotate crankshaft clockwise and check that plunger on timing chain tension-er is extended and timing chain tension-er slipper is pushed inward toward timing chain. If plunger on timing chain tension-er is not extended out against timing chain tension-er slipper, use screwdriver to push timing chain tension-er slipper toward plunger on timing chain tension-er until hook is released from pin.
17. To check valve timing, rotate crankshaft clockwise (viewed from timing chain end of engine) until crankshaft pulley timing mark (groove) aligns with "0" mark on timing chain cover and cylinder number one is at TDC on compression stroke. Cylinder number one is front cylinder at timing chain end of engine.
18. Ensure timing marks on camshaft sprockets are aligned and positioned in a straight line at top surface on timing chain cover. See Fig. 2. If timing marks are not as specified, rotate crankshaft clockwise one full revolution (360 degrees) and realign crankshaft pulley timing mark (groove) with "0" mark on timing chain cover and then recheck timing mark alignment. If timing marks are still not aligned, timing chain is incorrectly installed.
19. Before installing valve cover and gasket, apply sealant at specified areas on cylinder head. See Fig. 9. Install gasket, valve cover, seal washers, bolts and nuts. Tighten valve cover bolts/nuts to specification in sequence. See Fig. 52. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. Fill cooling system.
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Friday, January 14th, 2011 AT 3:50 PM
