24. Position the camshafts so that the dowel pins are at the top at the 12 o'clock position, then install the sprockets of both camshafts in their original positions by aligning the dowel pin hole on the back of each sprocket with the dowel pin on the corresponding camshaft. Apply thread locking compound to the sprocket bolt threads and install the washers. While holding each camshaft from turning as described in Step 20, tighten the bolts to the specified torque as shown in the Specifications at the beginning of this chapter.
25. If necessary, rotate the camshafts to correctly align the SMT marks on the sprockets (Fig. 6.8).
26. If the crankshaft has moved beyond TDC during this procedure, it should be turned until the keyway faces straight up and is at the 12 o'clock position: the line of symmetry of the keyway should be aligned with the centerline of the cylinders.
27. Install the fixed timing chain guide (fig. 6.17)
28. Place the timing chain on the crankshaft sprocket and align the colored link #1 (blue or orange) with the mark on the crankshaft sprocket (Fig. 6.28). Install the chain and crankshaft sprocket as a single assembly onto the engine, and then install the lower timing chain guide.
Fig. 6.28. Place the timing chain on the crankshaft sprocket (the crankshaft keyway faces straight up) and align chain link #1 with the mark on the crankshaft sprocket
Note: There are three colored links on the timing chain. Color link #1 is the link that is farthest away from the two colored links that are closer together.
29. Place the timing chain behind the lug of the fixed timing chain guide and place it on the exhaust camshaft sprocket, then on the intake camshaft sprocket, ensuring that the two chain links are aligned with the marks on the camshaft sprockets (Fig. 6.29). In doing so, completely eliminate any slack on the right side of the chain.
Fig. 6.29. Place the timing chain on the exhaust and intake camshaft sprockets, aligning the two chain links with the marks on the camshaft sprockets
30. Using one hand to remove the slack from the left side of the chain, install the tensioner arm/timing chain guide. Tighten the pivot bolt to the specified torque as shown in the Specifications at the beginning of this chapter. After installation, ensure that the tab on the arm cannot move past the stop on the cylinder head (Fig. 6.30).
Fig. 6.30. After installing the tensioner lever, make sure that the protrusion on the lever cannot move beyond the stop on the cylinder head
31. Again, check that piston #1 is still at TDC on the compression stroke and that the timing marks on the crankshaft and camshaft sprockets are aligned with the coloured links.
32. Install the crankshaft position sensor pulse wheel so that the "F" marking faces outward.
33. Apply a bead of RTV sealant to the timing chain cover sealing surfaces where the two center bolts pass and around the perimeter of the cover flange (fig. 6.33, a, b). Install the timing chain cover back into place on the engine and tighten the bolts according to their original position.
Fig. 6.33, a. Applying sealant to the timing chain cover
Fig. 6.33, b. Applying sealant to each side of the parting line between the cylinder head and the cylinder block
34. Tighten the bolts evenly in several stages to the prescribed torque specified in Specifications at the beginning of this chapter. Follow the sealant manufacturer's recommendations regarding assembly techniques and sealant curing times.
35. Again load and lock the timing chain tensioner in its "zero" position, proceeding as follows:
- a) Raise the ratchet pawl and push the plunger in until it stops (Fig. 6.35).
- b) Insert the hook on the tensioner body into the pin on the tensioner plunger to lock the plunger in place.
Fig. 6.35 Raise the ratchet pawl and push the plunger inward enough to allow the hook on the tensioner body to engage the pin on the plunger and lock the plunger in place
36. Lubricate the tensioner sealing ring with a small amount of oil and install the tensioner into the timing chain cover with the hook facing upwards (Fig. 6.36).
Fig. 6.36. Apply a small amount of oil to the tensioner sealing ring and insert the tensioner into the timing chain cover with the hook facing upwards
37. Install the crankshaft pulley/damper (see paragraph 11).
38. Rotate the engine slightly counterclockwise to engage the chain tension. As the engine rotates, the hook on the tensioner body should disengage from the pin on the plunger, allowing the plunger to spring out and tension the timing chain (Fig. 6.38). If the plunger does not spring out and tension the chain, press the lever and release the hook with a screwdriver.
Fig. 6.38 Rotate the engine counterclockwise to disengage the hook from the spring loaded pin on the tensioner, then rotate it clockwise to ensure the plunger is out towards the lever/chain guide
39. Turn the engine clockwise a few revolutions and set piston No.1 to the TDC position on the compression stroke again (see paragraph 3). Make sure that the timing mark on the crankshaft pulley/damper is aligned with the "0" mark on the timing chain cover and the marks on the camshaft sprockets are aligned and parallel to the top edge of the timing chain cover as shown (fig. 6.8).
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40. Tighten the timing chain cover fasteners to the specified torque as shown in the Specifications at the beginning of this chapter (Fig. 6.40). The remainder of the installation is carried out in the reverse order of removal.
Fig. 6.40. Sequence of tightening the bolts for fastening the hooks of the timing chain