Question about 1992 Toyota Land Cruiser

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Injetor pump removal for 1hz diesel

Hello, I am needing to know how to get the injector pump out. I have all the bolts,hoses and injetor lines off. I have removed the front sprocket and bolt. The injector pump moves back and forth but will not come out. I also notice that when I move the injector pump back and forth the the thread where the sprocket for the timing belt does not moveback and forth with it.I asume that there must be another bolt inside cover between sprocket thread and the pump but cant get it to split. I have undone a few bolts around the front where the timming belt runs as it looks like it is supposed to split there but cant get it to split. Do I have to take power steer pump out to get that bit to split? Cheers Luke

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  • 23 Answers

Hi there Luke. The sprocket gear of the pump is sitting on a taper lock on the pump shaft, you have to use a puller to get it off the shaft. Mount the puller to the threaded holes on the sprocket and when it is tight, give it a sharp crack with a hammer, it will then pop off.
Caution!!!!! Do not hit to hard the pump shaft has a transfer pump attached inside that is quite sensitive.
Before you do drastic things like removing the pump please read the attached manual on setting the timing, special tools are needed to reset the timing.injetor pump removal for 1hz diesel - 3d2b4ea.jpg

Posted on Aug 02, 2009

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Posted on Jan 02, 2017

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2.8 crd injection pump


alldata.com, log in and read that yet?
did you look at this near FSM?
the 21 steps, read them yet?. did you make it to step 21,?
quote
  1. Disconnect negative battery cable.
  2. Remove engine cover and bracket.
  3. Evacuate A/C system.
  4. Remove accessory drive belt.
  5. Remove cooling fan and fan shroud.
  6. Remove charge air cooler outlet hose to intake manifold.
  7. Remove fan support assembly.
  8. Remove timing belt outer cover.
  9. Using special tool VM.1055, remove high pressure injection pump sprocket retaining nut.
  10. Install feet from VM.1067 in injection pump sprocket as shown.
  11. Install inner flange of special tool VM.1067 on injection pump sprocket as shown. Secure flange to feet in injection pump sprocket with Allen bolts supplied with tool.
  12. Screw the high pressure injection pump sprocket holding plate assembly into flange of VM.1067. Using left hand threaded bolt supplied, secure holding pl
  13. Before servicing the vehicle, refer to the Precautions section. CAUTION High pressure lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 psi.(1600 bar). Use extreme caution when inspecting for high pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing personal injury or death. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system.
  14. ate assembly to timing belt inner cover.
  15. Disconnect A/C lines at compressor.
  16. Remove charge air inlet hose.
  17. Remove the EGR airflow control valve from the intake manifold.
  18. Remove high pressure injection pump to fuel rail high pressure line.
  19. Disconnect high pressure injection pump quantity control valve electrical connector.
  20. Disconnect fuel supply and return lines at high pressure injection pump.
  21. Remove alternator to intake manifold bracket.
21 Remove high pressure injection pump retaining nuts and remove pump.

Care must be taken not to bend the brake vacuum tube when removing high pressure pump.
unquote:


if you learn a short cut to that, please do post it.

Jan 20, 2014 | 2004 Jeep Liberty

1 Answer

I need timing marks on 2.2 toyota camry 2000


1. Remove the fan and generator V belt:
tdisline_542.jpg

tdisline_543.jpg 2. TIMING CHAIN (2az-FE Engine):
Before servicing the vehicle, refer to the Precautions Section.
Drain the engine oil.
Remove or disconnect the following:
Negative battery cable
Hood Right-side front wheel Engine under covers Right-side fender apron seal Front exhaust pipe Engine moving control rod and bracket Right-side engine mounting stay and bracket Accessory drive belt Engine appearance cover Engine wire Alternator Power steering pump, leave the hoses connected Ignition coils Ventilation hoses Cylinder head cover Turn the crankshaft pulley to set the No. 1 cylinder to TDC compression. Align the groove on the pulley with the timing mark -0- on the front cover. Remove the crankshaft pulley as follows:
1. TMC made: Use Special Tool 09213-54015 to hold the pulley to loosen the bolt. Use Special Tool 09950-50013 to remove the bolt and pulley.

2. TMMK made: Use Special Tool 09960-10010 to hold the pulley to remove the bolt. Use Special Tool 09950-40011 to remove the crankshaft pulley
tdisline_544.jpg Fig. Removing the crankshaft pulley-TMC-2.4L (2AZ-FE) engine
tdisline_545.jpg

Fig. Removing the crankshaft pulley-TMMK-2.4L (2AZ-FE) engine

Remove or disconnect the following:
Crankshaft position sensor Lower oil pan No. 1 chain tensioner Accessory drive belt tensioner

  • Support the engine with a suitable engine lifting device.
  • Remove or disconnect the following:
    Engine mounting insulators Right-side engine mounting bracket Stud bolt for the accessory drive belt tensioner from the block Front cover mounting bolts and nuts Front cover Crankshaft position sensor plate Timing chain tensioner slipper Timing chain vibration damper Timing chain Crankshaft timing sprocket
  • Turn the crankshaft counterclockwise by 90°, and align an adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
    tdisline_546.jpg
  • Fig. Align the adjusting hole of the oil pump drive sprocket with the oil pump groove-2.4L (2AZ-FE) engine
    tdisline_551.jpg

    Fig. Insert a bar to lock the sprocket in position-2.4L (2AZ-FE) engine
    Put a bar in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Remove the nut.

    Remove the bolt, chain tensioner and spring.

    Remove the chain tensioner, oil pump sprocket and No. 2 timing chain.

    To install:
    Set the crankshaft key into the left horizontal position. Turn the cutout of the drive shaft to the top

    tdisline_552.jpg

  • Fig. Align the crankshaft key and drive shaft cutout as shown for installation-2.4L (2AZ-FE) engine
    Align the yellow colored links with the timing marks of the sprocket as shown in the illustration.

  • Insert the sprockets with chain to the crankshaft and oil pump shaft.
  • Temporarily tighten the oil pump driven sprocket with the nut.
  • Insert the damper spring into the adjusting hole, and install the chain tensioner plate with the nut. Tighten to 9 ft. lbs. (12 Nm).
  • Align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
  • Put a bar in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position. Tighten the nut to 22 ft. lbs. (30 Nm).
  • Rotate the crankshaft counterclockwise by 90°, and align the crankshaft key to the top.
  • Install the timing chain vibration damper. Tighten to 80 inch lbs. (9 Nm).
  • Align the timing marks of the camshaft timing sprockets and bearing caps.
  • Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
  • Align the gold or orange colored link with the timing mark of the crankshaft timing sprocket.
  • Using Special Tool 09309-37010, tap in the sprocket.
  • Align the gold or yellow colored links with the timing marks of the camshaft timing gear and camshaft timing sprocket. Install the chain.
  • tdisline_553.jpg Fig. Align the marks of the sprockets and bearing caps to set the No. 1 cylinder at TDC-2.4L (2AZ-FE) engine
    tdisline_554.jpg Fig. Set the crankshaft set key facing upward-2.4L (2AZ-FE) engine
    tdisline_555.jpg Fig. Align the marked link of the timing chain with crankshaft sprocket timing mark-2.4L (2AZ-FE) engine
    tdisline_556.jpg Fig. Tap the crankshaft sprocket in with Special Tool 09309-37010-2.4L (2AZ-FE) engine
    tdisline_557.jpg Fig. Align the marked links of the timing chain with the camshaft sprockets during installation-2.4L (2AZ-FE) engine

    May 21, 2011 | Toyota Camry Cars & Trucks

    1 Answer

    Hi ive got a 1996 isuzu bighorn ive attempted to change the timing belt but the injector pump pulley moved when i took the belt off. i put it back where i thort it was and tried a tooth either way but no...


    Timing belt installation

    1. Ensure locking bolts located correctly [4] & [5] in the picture below:

    tdisline_32.jpg
    CS = Crankshaft
    CA = Camshaft
    IP = Injection Pump

    2. Ensure timing marks aligned [10].
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    NOTE: "ISUZU" lettering on belt should be readable from front of engine.

    4. Slacken tensioner pulley bolt [9]. Push tensioner pulley against belt.
    5. Ensure belt is taut between injection pump sprocket and tensioner pulley as well as crankshaft sprocket and camshaft sprocket.
    6. Position tensioner lever [8] against tensioner pulley housing.
    7. Remove locking bolts from sprockets [4] & [5].
    8. Apply a load of 10 ... 12 kg to tensioner lever. Use spring balance [11].
    9. Tighten tensioner pulley bolt to 80 Nm.
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    NOTE: DO NOT turn crankshaft clockwise during tensioning procedure!

    12. Fit tensioner lever to original position. Tighten nuts [12].
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    tdisline_33.jpg
    PLEASE DO RATE MY RESPONSE. THANKS!

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    1 Answer

    How do you remove toyota timeing chain


    Timing Chain and Gears Removal & Installation To Remove:
    toy_car_18_gen-p-s-mnts-cvrs-exhst_xp.gif

    Except XRS toy_car_18_eng_cmpnts+oil_pmp_loc_1zz-fe_xp.gif

    XRS toy_car_18_eng_cmpnts+oil_pmp_loc_2zz-ge_xp.gif

    toy_car_18_gen-p-s-mnts-cvrs-exhst_xp.gif

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    3. Remove the upper front fender apron insulator.
    4. Remove the upper radiator support insulator.
    5. Remove the right front wheel and tire assembly.
    6. Remove the right lower splash shield.
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    12. Remove the right engine mount. toy_car_18_eng_cylndr_hd_cvr_blts.gif

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    14. Remove the 4 ignition coils.
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    17. Remove the 4 bolts and the cylinder head shield (XRS).
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    23. Ensure that the marks on the camshaft timing sprockets are in straight line on the timing chain cover surface as shown. toy_car_18_eng_tmng_point_marks.gif

    24. If not turn the crankshaft 1 revolution (360°) and align the marks as above.
    25. Remove the crankshaft pulley toy_car_18_eng_rmv_crnk_sft_pos_snsr_blts.gif

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    32. Remove the 2 mounting nuts and remove the chain tensioner.
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      XRS toy_car_18_eng_tmng_chn_cvr_blts_2zz-ge.gif

    34. Remove the 11 mounting bolts and nut (except XRS).
    35. Remove the 12 bolts (XRS).
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      Note: If the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers. Position shop rags as shown to prevent damage.
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    41. Remove the 2 chain vibration damper mounting bolts. Remove the vibration damper toy_car_18_eng_tmng_cntrl_assy.gif

    42. Hold the camshaft hexagonal section with a wrench. Remove the sprocket mounting bolt.
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    Note: Be careful not to damage the cylinder head and valve lifter with the wrench.
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    Oct 19, 2010 | 2005 Toyota Corolla

    1 Answer

    How to replace water pump 2003 alero. 3400 engine.


    Removal & Installation 2.2L Engine To Remove:
    1. Disconnect the battery ground cable.
    2. If equipped with an automatic transmission, remove the exhaust manifold..
    3. Drain the cooling system.
    4. Raise and safely support the vehicle.
    5. Remove or disconnect the following:
      • Right front wheel and tire assembly.
      • Right front fender liner. chevy_cav_02-04_accescover.gif

      • Access plate on the water pump sprocket from the timing cover.
    6. Install J 43651 water pump sprocket holder or equivalent to the water pump sprocket.
    7. Use the access plate bolts to attach J43651 to the engine front cover.
    8. Remove or disconnect the following:
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      • Bolt that secures the engine block to the water pump.
      • Bolt that secures the engine front cover to the water pump.
      • Feed pipe that joins the thermostat housing to the water pump. chevy_cav_02-04_wp.gif

      • 2 Bolts that secure the water pump to the engine block.
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    1. Use a threaded stud in the hub to align the water pump sprocket.
    2. Install or connect the following:
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      • 2 of the bolts that secure the water pump sprocket to the water pump.
    3. Remove the threaded stud.
    4. Install the last bolt.
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    5. Remove J 43651.
    6. Install the access plate on the water pump sprocket to the timing cover.
    7. Install the access plate bolts.
      • Tighten the bolts to 18 in lbs (10 Nm).
    8. Install the front fender liner.
    9. Install the right front tire and wheel.
    10. If equipped with an automatic transmission, install the exhaust manifold.
    11. Fill the cooling system.
    12. Connect the battery ground cable.
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    Water pump 2.4L 87953070.gif

    1. Disconnect the negative battery cable
    2. Drain the engine coolant.
    3. Remove the exhaust manifold.
    4. Remove the coolant intake pipe as follows:
      1. Remove the coolant inlet pipe bolts.
      2. Remove the wheel and tire assembly.
      3. Remove the engine splash shield.
      4. Remove the bolts from the transaxle-to-engine block brace and remove the brace.
      5. Remove the radiator hose from the coolant inlet pipe.
      6. Remove the coolant inlet pipe to oil pan bolt.
      7. Remove the coolant inlet pipe, thermostat and seal.
    5. Lower the vehicle.
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    7. Remove the front timing chain cover and the chain tensioner.
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    9. Remove the water pump-to-timing chain housing nuts.
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    2. Install and hand tighten the pump cover mounting bolts.
    3. Install water pump cover assembly.
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    prev.gif next.gif

    Aug 31, 2010 | 2003 Oldsmobile Alero

    1 Answer

    Timing belt markings mazda B2500 1998


    Timing Belt, Sprockets & Front Cover Removal & Installation Timing belt To Remove:
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    5. Install the timing belt.
    6. Tighten the oil pump sprocket bolt. Torque to 30-40 ft-lb (40-55 Nm).
    7. Torque the camshaft bolt to 52-70 ft-lb (70-95 Nm).

    Jul 12, 2010 | 1998 Mazda Pickup

    2 Answers

    Need the step by step instructions and pictures on how to replace an water pump on an 2002 Oldsmobile Alero 2.4L


    Removal & Installation

    2.2L Engine
    1. Before servicing the vehicle, refer to the precautions section.
    2. Disconnect the negative battery cable.
    3. Drain the engine coolant.
    4. Remove or disconnect the following:
      Exhaust manifold, if equipped with n automatic transaxle Right front wheel Splash shield Water pump sprocket access plate from the timing cover

      fcd00e0.jpg

      Fig. Remove the water pump sprocket access plate from the timing cover -2.2L engine
    5. Attach Water Pump Sprocket Holding Tool J 43651to the sprocket using the access plate bolts to secure the tool to the engine front cover.
      Sprocket to water pump bolts Engine block to water pump bolt Engine front cover to water pump bolt Thermostat housing to water pump feed pipe 2 water pump to engine block bolts Water pump

      30965cd.jpg

      Fig. Water pump mounting-2.2L engine
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      Water pump and bolts Thermostat housing to water pump feed pipe Engine front cover bolt and engine block to water pump bolt. Tighten the bolts to 15 ft. lbs. (20 Nm) 2 of the water pump sprocket to water pump bolts
    2. Remove the threaded stud.
      Last water pump sprocket to water pump bolt and tighten the sprocket bolts to 89 inch lbs. (10 Nm).
    3. Remove the tool.
      Water pump sprocket access plate to the timing cover and tighten the bolts to 89 inch lbs. (10 Nm) Splash shield Right front wheel Exhaust manifold, if removed
    4. Fill the cooling system.
    5. Connect the negative battery cable.
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    1. Before servicing the vehicle, refer to the precautions section.
    2. Disconnect the negative battery cable.
    3. Drain the cooling system.
    4. Remove or disconnect the following:
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      f9cdfa8.jpg

      Fig. Exploded view of the water pump mounting-2.4L engine
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    Oct 22, 2009 | 2002 Oldsmobile Alero

    1 Answer

    Replacing the timing belt on a 1998 Nissan Quest and need to know cam shaft and crank shaft positions.


    go here for expert help on Villager & Quest

    http://groups.yahoo.com/group/villagerquest/

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    Item Part Number Description 1 — 40 Timing Chain/Belt Teeth 2 6256 Camshaft Sprocket , Front 3 — 43 Timing Chain/Belt Teeth 4 6306 Crankshaft Sprocket 5 6268 Timing Chain/Belt 6 6256 Camshaft Sprocket , Rear
    Removal
    1. Drain the cooling system. Refer to Section 03-03 for the procedure.
    1. Disconnect the battery ground cable (14301) .
    1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
    1. If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
    1. Remove the upper radiator hose bracket bolt.
    1. Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
    1. Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592) .
    1. Remove the main wiring harness from the upper engine front cover (6019) .
    1. Remove the eight upper engine front cover bolts and the upper engine front cover .
    1. Raise and support the vehicle.
    1. Remove the RH front wheel and tire assembly.
    1. Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775) .
    1. Use Strap Wrench 303-D055 (D85L-6000-A) or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
    1. Remove the water pump pulley from the water pump (8501) .
    1. Remove the crankshaft pulley (6312) . Refer to the procedure in this section.
    1. Remove the five lower engine front cover bolts and the lower engine front cover .
    2. Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
    3. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.
    4. Loosen the timing chain/belt tensioner nut.
    5. Remove the timing chain/belt .

    6. Installation
      NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned. NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts (6250) and the crankshaft (6303) . These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket .

      NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600) .

      Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprocket following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner .





    Sep 20, 2009 | 1998 Nissan Quest

    2 Answers

    Replacing timing belt on daewoo nubira 2000 model


    Instructions Difficulty: Moderate Things You’ll Need:
    • Set of ¼-inch drive sockets ¼-inch drive ratchet Set of ½-inch drive sockets ½-inch drive ratchet Set of 3/8-inch drive sockets 3/8-inch drive ratchet Set of metric wrenches Floor jack Jack stands
    Step1 Raise and support the vehicle on jack stands. Remove the intake air temperature wiring, the breather hose and intake air hose. Take off the air cleaner assembly. Step2 Remove the right wheel. Remove the accessory belts. Remove the crankshaft bolt and the crankshaft pulley. Remove the power steering bolts and the timing belt covers. Temporarily install the crankshaft bolt and turn the engine clockwise until the mark on the crankshaft pulley, which is a triangle stamped into the crank sprocket, is aligned with the corresponding triangular mark on the block. Step3 Make sure that the timing marks are aligned on the camshaft sprockets. These are a line on each sprocket that runs through a tooth on each sprocket. These lines should line up in the middle between each sprocket and point toward each other. If they do not line up, turn the crankshaft one more time and they will line up. It takes two turns of the crank to one complete revolution of the cam. Step4 Loosen the water pump bolts; using the 3/8-inch ratchet, turn the water pump clockwise away from the belt and loosely tighten the bolts to keep it there. Remove the timing beltmag-glass_10x10.gif. Make sure the timing marks are aligned and install the new belt starting on the right side from the crank sprocket and working counterclockwise. Keep all the belt tension on the right side away from the tensioner. Step5 Loosen the bolts in the water pump and rotate the water pump counterclockwise to apply tension to the belt. Watch the tensioner, which is above the water pump, and apply tension with the water pump until the pointer on the tensioner lines up with the notch above it. Lightly tighten the water-pump bolts. Step6 Turn the engine two more times and align the timing marks perfectly. Loosen the water-pump bolts and, using the ratchet, apply tension to the belt until the tensioner pointers are aligned. Tighten the water-pump bolts. Step7 Install the timing-belt covers and the bolts in the power-steering pump and tighten. Remove the crankshaft bolt and install the crank pulley and the bolt, then torque the crankshaft pulley bolt to 70 foot pounds of torque. Install all components in reverse order of removal.

    Mar 02, 2009 | 2000 Daewoo Nubira

    1 Answer

    Serpentine belt


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    This is a job for an experienced technician. Probably about a $300 job. Maybe more.

    Here is procedure for 1996:

    Removal
    1. Drain the cooling system. Refer to Section 03-03 for the procedure.
    1. Disconnect the battery ground cable (14301).
    1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
    1. If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
    1. Remove the upper radiator hose bracket bolt.
    1. Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
    1. Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592).
    1. Remove the main wiring harness from the upper engine front cover (6019).
    1. Remove the eight upper engine front cover bolts and the upper engine front cover.
    1. Raise and support the vehicle.
    1. Remove the RH front wheel and tire assembly.
    1. Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775).
    1. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
    1. Remove the water pump pulley from the water pump (8501).
    1. Remove the crankshaft pulley (6312). Refer to the procedure in this section.
    1. Remove the five lower engine front cover bolts and the lower engine front cover.
    2. Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
    2acab54.gif
    18. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.

    If the timing chain/belt is to be reused, mark the direction of rotation on the timing chain/belt.

    19. Loosen the timing chain/belt tensioner nut.

    1. Remove the timing chain/belt.
    Installation
    NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned.



    stv~us~en~file=ani_caut.gif~gen~ref.gif CAUTION: Pay special attention to the tooth shape of the timing belt. The current timing belts are not interchangeable with the timing belts from the 1993 model year. The 1993 model year uses a square or trapezoidal tooth timing belt while the current model year uses a rounded tooth design. The design change was made to extend the service life of the timing belt from 60,000 miles for the square or trapezoidal toothed belt to 105,000 miles for the rounded tooth belt. If the proper timing belt is not used, the customer may complain of a "whining" noise coming from the engine compartment. If the camshaft sprocket has a square cut in the valley of the gear tooth, it will require a square or trapezoidal tooth timing belt. If the camshaft sprocket has a rounded cut in the valley of the gear tooth, it will require a rounded tooth timing belt.
    NOTE: If a new timing chain/belt is to be installed, make sure that the arrow is pointing away from the engine. If a timing chain/belt is to be reused, make sure that the directional arrow that was marked during disassembly is facing the correct direction.

    NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts and the crankshaft. These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket.

    NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600).

    Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprockets following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner.

    1. While holding the timing chain/belt tensioner with an Allen wrench, loosen the timing chain/belt tensioner nut.
    1. Allow the timing chain/belt tensioner to put pressure on the timing chain/belt.
    1. Use an Allen wrench to turn the timing chain/belt tensioner 70-80 degrees clockwise and tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 lb-ft).

      1. Rotate the crankshaft (6303) clockwise twice and align the No. 1 piston to Top Dead Center (TDC) on its compression stroke.
      1. Apply 98N (22 lbs) of force on the timing chain/belt between the rear camshaft sprocket and the timing chain/belt tensioner.
      2. NOTE: An assistant may be needed to adjust the timing chain/belt.

        While holding the timing chain/belt tensioner steady with an Allen wrench, loosen the timing chain/belt tensioner nut. Remove the Allen wrench and adjust the timing chain/belt tensioner as follows:
        1. Install a 0.35mm (0.0138 inch) thick and 12.7mm (0.500 inch) wide feeler gauge as shown.

    1. Turn the crankshaft clockwise to position the feeler gauge between the timing chain/belt tensioner and the timing chain/belt

    1. Tighten the timing chain/belt tensioner nut to 43-58 Nm (32-43 lb-ft).
    1. Turn the crankshaft clockwise to remove the feeler gauge from between the timing chain/belt tensioner and the timing chain/belt.
    1. Rotate the crankshaft clockwise twice and align the No. 1 piston to TDC on its compression stroke.
    1. Apply 98N (22 lbs) of force on the timing chain/belt between the rear and front camshaft sprocket.
      1. Measure the timing chain/belt deflection. Timing chain/belt deflection should be between 13-15mm (0.51-0.59 inch). If timing chain/belt deflection is not within specification, repeat steps 3-11. If the timing chain/belt cannot be adjusted to within specification, the timing chain/belt will have to be replaced.
      1. Position the lower engine front cover and install the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in).
      1. Install the outer timing chain/belt guide and the crankshaft pulley. Refer to the procedure in this section.
      1. Position the water pump pulley on the water pump and install the four water pump pulley bolts
      1. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley, and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft).
      1. Position the RH outer engine and transmission splash shield and install the four RH outer engine and transmission splash shield bolts and two screws.
      1. Install the RH front wheel and tire assembly. Tighten the lug nuts (1012) to 98-118 Nm (72-87 lb-ft).



    Feb 14, 2009 | 1993 Mercury Villager

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