Note: The engine is timed top-dead centre exhaust stroke.
- Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
- Install a friction washer (1), if equipped.
- Install the timing chain drive sprocket (3) to the crankshaft with the timing mark (2) in the 5 o'clock position and the front of the sprocket facing out.
- Install a second friction washer (1), if equipped.
Note: There are two possible chain configurations for the engine. Both configurations use a unique chain link to line up with the intake camshaft actuator timing mark. The first design uses a unique link colour (1). The second design uses a black anodized link (3) with uniquely coloured links on either side (2).
- Orient the chain so that the colored links are visible.
- Determine the configuration of the timing chain.
- For the 1st design timing chain, assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely coloured link (1).
- For the 2nd design timing chain, assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the black anodized timing link (3) that has uniquely coloured links on either side (2).
- Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
- Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
Note: Always use NEW actuator bolts.
- Hand tighten the new intake camshaft actuator bolt.
- Route the timing chain around the crankshaft sprocket and line up the coloured link (1) with the timing mark on the crankshaft sprocket, approximately in the 5 o'clock position.
- Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
Caution: Refer to Fastener Caution in the Preface section.
- Install the adjustable timing chain guide (1) down through the opening in the cylinder head and install the adjustable timing chain bolt and tighten to 10 N·m (89 lb in).
- Install the exhaust camshaft actuator (1) into the timing chain with the timing mark lined up with the coloured link.
Note: Always install NEW actuator bolts.
- Install the exhaust camshaft actuator (1) onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
- Using a 23-24 mm open ended wrench, rotate the exhaust camshaft clockwise until the dowel pin in the camshaft actuator goes into the camshaft slot.
- When the actuator (1) seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
- Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
- Install the fixed timing chain guide (1) and bolts and tighten to 12 N·m (106 lb in).
- Install the upper timing chain guide (1) and bolts and tighten to 10 N·m (89 lb in).
- Reset the timing chain tensioner by performing the following steps:
| 22.1. | Remove the snap ring. |
| 22.2. | Remove the piston assembly from the body of the timing chain tensioner. |
| 22.3. | Install the EN-45027-2 (2) tensioner in a vice. |
| 22.4. | Install the notch end of the piston assembly into the EN-45027-2 (2) tensioner . |
| 22.5. | Using the EN-45027-1 (1) tensioner , turn the ratchet cylinder into the piston. |
| 22.6. | Reinstall the piston assembly into the body of the tensioner. |
| 22.7. | Install the snap ring. |
- Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
- Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
Note: Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak.
- Install the timing chain tensioner assembly (1) and tighten to 75 N·m (55 lb ft).
Note: The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet.
- The crankshaft balancer must be installed in order to release the tensioner. Refer to
Crankshaft Balancer Installation : LE5 or LE9 .
- Install EN-48953 locking tool (1) and tighten the bolts into the cylinder head to 10 N·m (89 lb in).
- Using a torque wrench, tighten the intake camshaft actuator bolt to 30 N·m (22 lb ft) , plus 100 degrees using the EN 45059 meter .
- Using a torque wrench, tighten the exhaust camshaft actuator bolt to 30 N·m (22 lb ft) , plus 100 degrees using the EN 45059 meter .
- Remove EN-48953 locking tool.
- Install the timing chain oiling nozzle (1) and tighten the bolt to 10 N·m (89 lb in).
- Apply sealant to the thread of the timing chain guide bolt access hole plug . Refer to Adhesives, Fluids, Lubricants, and Sealers .
- Install the timing chain guide bolt access hole plug (1) and tighten to 90 N·m (66 lb ft).
