Timing Component Alignment Marks: Locations
NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage may occur.
NOTICE: Failure to position the No. 1 piston at Top Dead Center (TDC) may result in damage to the engine.
NOTICE: Turn the crankshaft in the normal direction of rotation only, or the engine may be damaged.
Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
Remove the timing peg plug.
NOTE: The Crankshaft Timing Peg will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain in the TDC position during the crankshaft pulley removal and installation.
Install the Crankshaft Timing Peg.
NOTICE: Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position may cause severe damage to the valves and pistons.
NOTICE: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The new diamond washers must be installed correctly, or severe engine damage may result.
Install the new diamond washers and the oil pump chain and sprockets.
- The crankshaft sprocket flange must be facing away from the engine block.
NOTE: The oil pump chain sprocket must be held in place.
NOTE: Sprockets must turn freely on the camshafts.
Position the camshaft sprockets and loosely install the bolts. Do not tighten the sprocket bolts at this time.
Install the timing chain.
NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.
Install the Camshaft Alignment Plate in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
NOTICE: The Camshaft Alignment Plate is for camshaft alignment only. Using this tool to prevent engine rotation may result in engine damage.
NOTE: Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.
Tighten the camshaft sprocket bolts.
- Tighten to 72 Nm (53 lb-ft).
NOTE: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil to the seal area prior to installing.
Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
NOTICE: The crankshaft must remain in the Top Dead Center (TDC) position during installation of the pulley bolt or damage to the engine may occur. Therefore, the crankshaft pulley must be held in place with the Drive Pinion Flange Holding Fixture and the Adapter for 205-126 and the bolt should be installed using hand tools only.
NOTE: Do not reuse the crankshaft pulley bolt.
Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley in place.
Remove the 6 mm x 18 mm bolt.
Remove the Crankshaft Timing Peg.
Remove the Camshaft Alignment Plate.
NOTE: Only turn the crankshaft in the normal direction of rotation.
Turn the crankshaft clockwise one and three-fourths turn.
Install the Crankshaft Timing Peg.
NOTE: Only turn the crankshaft in the normal direction of rotation.
Turn the crankshaft clockwise until the crankshaft contacts the Crankshaft Timing Peg.
NOTICE: Only hand-tighten the 6 mm x 18 mm bolt or damage to the front cover may occur.
Using the 6 mm x 18 mm bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, correct the engine timing.
Install the Camshaft Alignment Plate to check the position of the camshafts.
- If it is not possible to install the Camshaft Alignment Plate, correct the engine timing.
Remove the Camshaft Alignment Plate.
Remove the 6 mm x 18 mm bolt.
Remove the Crankshaft Timing Peg.
Install the timing peg plug.
- Tighten to 20 Nm (177 lb-in).