Special Tools
• | EN 46330 Timing Chain Tensioner Retaining Pin |
• | J 41478 Crankshaft Front Oil Seal Installer |
• | J 41558 Crankshaft Sprocket Remover |
• | J 41665 Crankshaft Balancer and Sprocket Installer |
Removal Procedure
- Remove the oil pump. Refer to
Oil Pump, Screen, and Crankshaft Oil Deflector Replacement.
- Remove the starter motor. Refer to
Starter Replacement.
Caution: Refer to Fastener Caution in the Preface section.
Note: Ensure that the teeth of the
J 42386-A mesh with the teeth of the engine flywheel.
- Install the
J 42386-A (1) and bolts. Use one M10-1.5 x 120 mm and one M10-1.5 x 45 mm bolt for proper tool operation.
Tighten
Tighten the
J 42386-A bolts to 50 N·m (37 lb ft).
- Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned.
Caution: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
- Remove the camshaft sprocket bolt (206).
- Remove the camshaft sprocket (205) and timing chain (208).
- Remove the timing chain tension bolts (231) and tensioner (232).
- Using the
J 41816-2 (1), the
J 41558 (2), bolts (3) and the
J 8433 (4) in order
to remove the crankshaft sprocket.
- Remove the crankshaft sprocket (207).
- Remove the crankshaft sprocket key, if required.
Installation Procedure
- Install the key into the crankshaft keyway, if previously removed.
- Tap the key (122) into the keyway until both ends of the key bottom onto the crankshaft.
- Install the crankshaft sprocket (207) onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
- Use the
J 41478 (1) and the
J 41665 (2) in order to install the crankshaft sprocket. Install the sprocket onto the crankshaft until
fully seated against the crankshaft flange.
- Compress the timing chain tensioner guide and install the
EN 46330 .
- Install the timing chain tensioner (232) and bolts (231).
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
Note:
• | The sprocket teeth and timing chain must mesh. |
• | The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. |
- Position the camshaft sprocket (205) so the timing mark is in the 6 o'clock position.
- Install the camshaft sprocket (205), timing chain (208), and bolt (206).
- Inspect the sprockets for proper alignment. The mark on the camshaft sprocket (1) should be located in the 6 o'clock position and the mark on the crankshaft sprocket (2) should be located in the 12 o'clock
position.
- Remove the
EN 46330 .
- Tighten the camshaft sprocket bolt
Tighten
- Tighten the bolt a first pass to 90 N·m (66 lb ft).
- Tighten the bolt a final pass an additional 40 degrees using
J 45059 .
- Remove the
J 42386-A (1) and bolts.
- Install the starter motor. Refer to
Starter Replacement.
- Install the oil pump. Refer to
Oil Pump, Screen, and Crankshaft Oil Deflector Replacement.