Spark

Camshaft Timing Chain Adjustment

Special Tools

For equivalent regional tools, refer to Special Tools

1. Remove the following attachment parts if still installed at the engine:

1.1.	Remove the generator. Refer to Generator Removal .

1.2.	Remove the exhaust gas recirculation valve vacuum tank . Refer to Exhaust Gas Recirculation Valve Vacuum Tank Removal .

1.3.	Remove the alternator bracket . Refer to Alternator Bracket Removal .

1.4.	Remove the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Removal .

1.5.	Remove the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Removal .

1.6.	Remove the intake manifold. Refer to Inlet Manifold Removal .

1.7.	Remove the diesel fuel separator. Refer to Diesel Fuel Separator Removal .

1.8.	Remove the vacuum pump . Refer to Vacuum Pump Removal .

1.9.	Remove the fuel injection fuel feed pipe from fuel injection pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Removal - Fuel Injection Pump to Fuel Rail .

1.10.

Remove the fuel injection pump. Refer to Fuel Injection Pump Removal .

1.11.

Remove the fuel injection fuel feed pipe from fuel rail to fuel injectors. Refer to Fuel Injection Fuel Feed Pipe Removal - Fuel Rail to Fuel Injector .

1.12.

Remove the fuel rail. Refer to Fuel Rail Removal .

1.13.

Remove the sump. Refer to Sump Removal .




2. Remove the camshaft cover core hole plug - intake (1) from the camshaft housing (2).
3. Remove the camshaft cover core hole plug - exhaust (3) from the camshaft housing (2).
4. Clean the threads from the camshaft cover core hole plugs and the camshaft housing.



5. Remove the 4 positive crankcase ventilation cover bolts (3).
6. Remove the positive crankcase ventilation cover (1).
7. Remove the positive crankcase ventilation cover gasket (2).

1. Install the 2EN-50515 fixing tools  (1) on exhaust and intake side.




Note: Engage the EN-50515 fixing tool at the intake camshaft

2. Apply pressure at EN-50515 fixing tool  (arrow) and carefully turn the crankshaft at the crankshaft sprocket bolt (2) in the direction of engine rotation (arrow), until EN-50515 fixing tool  (1) engages in the intake camshaft.



3. Install EN-662-C holding wrench  (2) to counterhold the crankshaft.
4. Install 2 bolts.
5. Loosen the crankshaft sprocket bolt (1)

Note: Counterhold at the camshaft sprocket. Second person required.





Note: The holding pins from the EN-50514 holder  (1) must be installed exactly in the holes (arrows) from the camshaft sprocket (2).

6. Install EN-50514 holder  (1) with the EN-956-1 extension to counterhold the camshaft sprocket (2).



7. Loosen the camshaft intake sprocket bolt (1).
8. Rotate the exhaust camshaft 15° against the direction of engine rotation.
9. Turn the exhaust camshaft at the camshaft sprocket bolt in direction of the engine rotation until the EN-50515 fixing tool engages in the exhaust camshaft.
10. Remove and DISCARD the camshaft intake sprocket bolt (1).
11. Install the NEW camshaft intake sprocket bolt (1).

Caution: Refer to Fastener Caution in the Preface section.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

Note: Counterhold the camshaft sprocket withEN-50514 holder .

12. Tighten the NEW camshaft intake sprocket bolt (1) to 100 N·m +45° (74 lb ft +45°).



13. Counterhold crankshaft with EN-662-C holding wrench  (2).
14. Tighten the crankshaft sprocket bolt (1) to 50 N·m +90° (37 lb ft +90°).




Note: The holding pins from the EN-50514 holder  (1) must be installed exactly in the holes (arrows) from the camshaft sprocket (2).

15. Install EN-50514 holder  (1) with the EN-956-1 extension to counterhold the camshaft sprocket (2).

Note: Do not remove the camshaft sprocket bolt (3).

16. Loosen the camshaft sprocket bolt (3).
17. Remove the EN-50514 holder (1).




Note: If the transmission is installed.

18. Carefully turn the crankshaft until the EN-46785 fixing tool  (1) engages in the flywheel.




Note: If the transmission is removed.

19. Carefully turn the crankshaft until the EN-50516 fixing tool  (1) engages in the flywheel and the engine block.



20. Remove and DISCARD the camshaft sprocket bolt (3).
21. Install the NEW camshaft sprocket bolt (3).

Note: The holding pins from the EN-50514 holder  (1) must be installed exactly in the holes (arrows) from the camshaft sprocket (2).

22. Install EN-50514 holder  (1) with the EN-956-1 extension to counterhold the camshaft sprocket (2).

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

23. Tighten the NEW camshaft sprocket bolt (3) to 100 N·m +45° (74 lb ft +45°).
24. Remove the EN-50514 holder (1).



25. Loosen the crankshaft sprocket bolt (1).



26. Install EN-50519 fixing tool  (2) to balance shaft driven gear (1).



27. Counterhold crankshaft with EN-662-C holding wrench  (2).
28. Remove and DISCARD the crankshaft sprocket bolt (1).
29. Install the NEW crankshaft sprocket bolt (1).

Caution: Refer to Fastener Caution in the Preface section.

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

30. Tighten the NEW crankshaft sprocket bolt (1) to 50 N·m +90° (37 lb ft +90°).



31. Remove the EN-50519 fixing tool  (2) from the balance shaft driven gear (1).



32. Remove the 2 EN-50515 fixing tools  (1).




Note: If the transmission is installed.

33. Remove the EN-46785 fixing tool (1).




Note: If the transmission is removed.

34. Remove the EN-50516 fixing tool  (1).
35. Inspect the camshaft timing chain. Refer to Camshaft Timing Chain Inspection .

1. Install the positive crankcase ventilation cover gasket (2).
2. Install the positive crankcase ventilation cover (1).

Caution: Refer to Torque-to-Yield Fastener Caution in the Preface section.

3. Install the 4 positive crankcase ventilation cover bolts (3) and tighten in a cross sequence to 10 N·m (89 lb in).



4. Clean the threads from cylinder head core hole plug and camshaft housing.
5. Install the cylinder head core hole plug exhaust side (3) to the camshaft housing (2) and tighten to 25 N·m (18 lb ft).
6. Install the cylinder head core hole plug intake side (1) to the camshaft housing (2) and tighten to 25 N·m (18 lb ft).
7. Install the following attachments parts if still removed from the engine:

7.1.	Install the oil pan. Refer to Sump Installation .

7.2.	Install the fuel rail. Refer to Fuel Rail Installation .

7.3.	Install the fuel injection fuel feed pipe from fuel rail to fuel injectors. Refer to Fuel Injection Fuel Feed Pipe Installation - Fuel Rail to Fuel Injector .

7.4.	Install the fuel injection pump. Refer to Fuel Injection Pump Installation .

7.5.	Install the fuel injection fuel feed pipe from fuel injection pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Installation - Fuel Injection Pump to Fuel Rail .

7.6.	Install the vacuum pump . Refer to Vacuum Pump Installation .

7.7.	Install the diesel fuel separator. Refer to Diesel Fuel Separator Installation .

7.8.	Install the inlet manifold. Refer to Inlet Manifold Installation .

7.9.	Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Installation .

7.10.

Install the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Installation .

7.11.

Install the alternator bracket . Refer to Alternator Bracket Installation .

7.12.

Install the exhaust gas recirculation valve vacuum tank. Refer to Exhaust Gas Recirculation Valve Vacuum Tank Installation .

7.13.

Install the generator. Refer to Generator Installation .