Timing Alignment:
NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in a procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information See: Engine > Procedures.
NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
NOTE: The Crankshaft TDC Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position until the timing drive components and crankshaft pulley are installed.
Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center (TDC).
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NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled.
NOTE: The original adjustment shims must be installed in their original positions.
NOTE: Confirm by visual inspection that there is no damage to the balancer unit gear and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit.
Install the adjustment shims in their original positions on the seat faces of the balancer unit.
With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
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NOTICE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, can cause severe damage to the valves and pistons.
NOTE: Install a new crankshaft sprocket diamond washer on both sides of the crankshaft sprocket.
Install the crankshaft sprocket, new crankshaft sprocket diamond washers, oil pump chain and oil pump sprocket.
The crankshaft sprocket flange must be facing away from the engine block.
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Install the oil pump chain, sprocket and bolt.
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NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
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Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
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Install the timing chain.
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Saturday, September 15th, 2018 AT 10:50 AM
