1. Disconnect the battery negative cables from the batteries.

•	For the front battery, refer to Battery Cable Replacement in Engine Electrical.

•	For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.

2. Remove the air cleaner assembly from the vehicle.
3. Remove the fan shroud from the radiator. Refer to Fan Shroud Replacement in Engine Cooling.
4. Remove the surge tanks from the vehicle. Refer to Surge Tank (Diesel) Replacement in Engine Cooling.
5. Remove the drive belt from the pulleys. Refer to Drive Belt Replacement .
6. Remove the water pump from the engine front cover. Refer to Water Pump Replacement in Engine Cooling.
7. Remove the engine front cover from the engine block. Refer to Engine Front Cover Replacement .
8. Remove the bolt from the timing chain sprocket to the camshaft.



9. Remove the fuel injection pump drive gear from the timing chain sprocket.



10. Remove the timing chain and sprocket from the camshaft.



11. Remove the sprocket from the crankshaft.

Important: Replace the wood drift key if there are signs of excessive wear or damage. Do not try to repair the wood drift key.

12. Remove the wood drift key if damaged from the camshaft.

Notice: Perform TDC Offset Recovery procedure if the timing chain, timing gears, engine front cover, crankshaft position sensor, crankshaft or other components affecting the timing are replaced.

1. Install the crankshaft sprocket to the crankshaft.



2. Align the timing marks.



3. Install the camshaft sprocket with the timing chain.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the timing chain sprocket bolt to the camshaft.

Tighten
Tighten the bolt to 171 N·m (125 lb ft).

5. Install the engine front cover to the engine block. Refer to Engine Front Cover Replacement .



6. Install the fuel injection pump drive gear to the camshaft.

Tighten
Tighten the bolts to 25 N·m (20 lb ft).

7. Install the water pump to the engine front cover. Refer to Water Pump Replacement in Engine Cooling.
8. Install the drive belt on the pulleys. Refer to Drive Belt Replacement .
9. Install the fan shroud on the radiator. Refer to Fan Shroud Replacement in Engine Cooling.
10. Install the surge tank in the vehicle. Refer to Surge Tank (Diesel) Replacement in Engine Cooling.
11. Install the air cleaner assembly in the vehicle.
12. Connect the battery negative cables to the batteries.

•	For the front battery, refer to Battery Cable Replacement in Engine Electrical.

•	For the auxiliary battery, refer to Battery Cable Replacement in Engine Electrical.

13. Check the fuel injection pump timing. Refer to Fuel Injection Pump Timing Adjustment in Engine Controls--6.5L.
14. Perform TDC offset timing adjustment. Refer to Fuel Injection Pump Top Dead Center Offset Adjustment in Engine Controls-6.5L.