Timing Chain: Removal

NOTE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).

With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
Remove the following items:
1. Remove the high-pressure fuel pump drive unit. Refer to: High-Pressure Fuel Pump Drive Unit .
2. Remove the engine front cover. Refer to: Engine Front Cover .
Remove the special tool. Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.

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NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Install the special tool into the slots on the back of the camshafts.

Install Special Service Tool: 303-1565 Alignment Tool, Camshaft.

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NOTE: Use an open-ended wrench to prevent the component from turning.

Loosen the exhaust VCT unit bolt.

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NOTE: Use an open-ended wrench to prevent the component from turning.

Loosen the intake VCT unit bolt.

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NOTE: If equipped with cast iron timing chain tensioner.
1. Using a small pick, release and hold the ratchet mechanism.
2. While holding the ratchet mechanism in the released position, compress the tensioner by pushing the timing chain arm toward the tensioner.
3. Insert a holding pin into the hole to retain the tensioner.
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NOTE: If it is necessary to install a new timing chain tensioner, a cast iron tensioner is to be replaced with an aluminum tensioner (6K254). The existing bolts must be discarded and replaced with new bolts (6K282).

NOTE: If equipped with cast iron timing chain tensioner.

Remove the bolts and the timing chain tensioner.

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NOTE: If equipped with aluminum timing chain tensioner.

Remove the bolts and the timing chain tensioner.

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- Remove the timing chain tensioner arm.
- Remove the timing chain.
- Remove the bolts and the timing chain guide.

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