1966 chrysler 300/383 engine camshaft timing installation procedure with piston @ top dead center compression of #1 cylinder

Getting the engine to top dead center (TDC) on the compression stroke is an important step when replacing the timing chain on a 2008 Hyundai Sonata 2.4L. Here are the general steps to follow:
1. Locate the timing marks: Look for the timing marks on the crankshaft pulley and the camshaft sprocket. The crankshaft pulley should have a mark on it, and the camshaft sprocket should have two marks that need to be aligned.
2. Rotate the engine: Rotate the engine by hand using a socket wrench on the crankshaft bolt. Turn the engine clockwise until the timing marks on the camshaft sprocket are aligned.
3. Check the piston position: Remove the spark plug from the number one cylinder and use a long screwdriver to feel for the position of the piston. When the piston is at the top of its stroke, you will feel resistance.
4. Adjust the position: If the piston is not at TDC on the compression stroke, rotate the engine again until it is. You may need to rotate the engine several times to get it in the correct position.
5. Double-check the timing marks: Once the piston is at TDC on the compression stroke, double-check the timing marks on the crankshaft pulley and the camshaft sprocket to ensure they are still aligned.
Once you have confirmed that the engine is at TDC on the compression stroke, you can proceed with installing the new timing chain. It's important to follow the manufacturer's instructions carefully and to torque all bolts to the correct specifications. If you are unsure about any step of the process, it may be best to consult with a mechanic or seek further guidance from an expert source.

Locate the top dead center by checking the air flow out of cylinder #1. As the #1 piston comes to top dead center the flow will stop and watch the top of the piston until it starts to go down. It it has a distributor install it as it engages the gear on the camshaft. As it is completely installed it will rotate slightly as it engages the camshaft gear. There is a timing mark on the vibration damper pulley and when the pointer is on that mark it will be on top dead center so rotate the distributor until the rotor is pointing at the wife for #1 cylinder. If there is no distributor the timing mark will indicate top dead center.

Camshaft is timed with the crankshaft and the distributor is timed to both. The cam rotates at half the speed of the crankshaft.
#1 piston must be at TDC (Top Dead Center) on the compression stroke to be timed correctly. The cam must be "timed" or installed correctly at this point, and "timed" to the crankshaft rotation. The distributor is timed to the #1 piston at this point. This is true for all engines.(there may be some odd engines that are timed differently?)

You have to put the number 1 cylinder at Top Dead Center of the compression stroke, and then you install the distributor with the rotor pointing to the #1 spark plug wire tower that is on the distributor cap.

Pull the spark plug from number 1 cylinder. You need a helper to turn the engine over by hand (using a socket on the crank pulley), or he can bump the starter over in very short bursts. Put your finger over the spark plug hole. When the piston is rising on the compression stroke, you will feel air pressure on your finger. Now look at the crank pulley and turn the engine on over until the zero degrees mark lines up on the timing pointer. Or you can stick a long straw or similar into the spark plug hole (don't let it drop into the cylinder!) to feel when the piston is at top of travel...see, you feel for pressure build up with finger (piston is rising on compression stroke), when you feel it, turn engine on over by hand until the piston is at top of travel-that is TDC of compression stroke. Now install distributor so that rotor ends up pointing directly to number 1 spark plug wire tower. Then follow firing order -as the rotor turns, it will follow the firing order around the dist. cap.
There are two top dead centers of each piston, tdc of compression stroke and tdc of exhaust stroke- to time the engine, you need tdc of compression-that is when the spark plug fires in the cylinder, so that is when you want the distributor in with the rotor pointing to #1.

Okay, you have to set the number 1 cylinder at TDC of its
compression stroke, and then drop in the distributor so the rotor is pointing to the #1 spark plug wire tower. This should start the car, then you could set the timing to spec with a timing light.

There are two TDC's of a cylinder- the compression stroke and the exhaust stroke. To find the compression stroke, take out the #1 cylinder spark plug. Put your finger over the hole. Now either turn the engine over by hand (with a socket on the crankshaft pulley-turn clockwise), OR have a helper bump the starter over in as short bursts as possible. As soon as you feel pressure on your finger- stop turning- the piston in #1 is rising on its compression stroke. Now check the timing pointer or scale by the crank pulley. Turn the engine slowly on over until the notch or mark on the crank pulley is right on the zero degrees mark on the scale. This is TDC of compression stroke-the piston is at top of travel in the cylinder. Put the distributor in so the rotor will be pointing to the #1 spark plug wire.

Check your owner's manual for the recommended mileage for replacing your timing chain. Replacement for a Nissan Maxima is 60,000 miles.2 Locate the timing chain. Replace it if the automatic chain adjuster (also known as the tensioner) is damaged or worn.3 Release the pressure in the fuel system, drain the cooling system and disengage the negative battery cable. 4 Undo the upper radiator hose, engine drive belts, power steering pulley and pump with bracket, air duct, passenger front wheel and engine side and undercovers, front exhaust pipe, cylinder head front mounting bracket and head cover, rocker cover, distributor and distributor cap and spark plugs.5 Take off the intake manifold support and move the No. 1 piston at "Top Dead Center" (TDC) of the compression stroke.6 Disconnect the cylinder head front cover, water pump pulley, thermostat housing, upper and lower tensioner and slack side timing chain guide, idler sprocket bolt, camshaft sprocket bolts, sprockets, mounting caps and camshafts. 7 Disengage the cylinder head with the manifolds, idler sprocket shaft, upper timing chain, center crossmember, oil pan and strainer assembly, crankshaft pulley, engine front mount and bracket and the front timing cover. Remove the oil seal and unfasten the timing chain cover, idler and crankshaft sprockets and the oil pump drive spacer. 8 Unfasten the timing chain guide. install Your Timing Chain 1 Grease the oil seal lip with engine oil and place it in the front cover. Verify that the No. 1 piston is at "Top Dead Center" (TDC) of the compression stroke. 2 Reconnect the crankshaft sprocket (marks should point toward the engine's front), oil pump drive spacer and timing chain guide and the lower timing chain. Line up all mating marks.3 Hook up the crankshaft sprocket and pulley, lower timing chain, front cover assembly, engine mount and front mounting bracket, oil strainer and pan assembly and center crossmember.4 Reattach the upper timing chain, idler sprocket (to the back side), cylinder head assembly, idler sprocket bolt and exhaust and intake camshafts. Place the intake camshaft knock pin at 9 o'clock and the exhaust pin at noon. Connect the camshaft bearing caps and distributor brackets and secure all mounting bolts.5 Eliminate any old material from the pan and cylinder block mounting surfaces. Rub on a 3.5 to 4.5mm bead of liquid gasket over the oil pan and cylinder block.6 Attach the upper timing chain to the idler sprockets and secure the cylinder head bolts.7 Refill the cooling system. Hook up the negative battery cable and any other disconnected items. Start the engine and look for leaks.

below are the instruction you well need to remove head .....good luck Removal Procedure

1. Remove the air cleaner element.
2. Remove the air cleaner outlet resonator. .
3. Remove the powertrain control module (PCM) and engine wire harness bracket and related hoses and connections.
4. Remove the generator.
5. Remove the intake manifold.
6. Remove the exhaust manifold. Do not remove the exhaust pipe from the manifold. Only have the manifold pushed off to the side of the engine.
7. Position the A/C line out of the way towards the front of the vehicle.
8. Disconnect the following cross-vehicle engine wiring harness connectors:
• Engine coolant temperature sensor • Manifold absolute pressure (MAP) sensor • Ignition coils • Harness clamps at power steering pump • Wiring harness fastener at the right front inner fender • Throttle body • Camshaft sensors • Camshaft actuators • Fuel rail • Heated oxygen sensor (HO2S)
9. Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
10. Remove the camshaft cover.
    
11. Partially drain the cooling system.


12. Before performing one of the top dead center (TDC) procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 25 mm (1 in) open end wrench on the camshaft hexes to hold the camshaft from turning. DO NOT remove the bolts.
13. Perform one of the following methods for the service timing procedure.
    
14. First Method--Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder.
    
15. First Method (continued)--The TDC indicator tool graduation marks on the shaft should note top of the piston stroke.
    
16. First Method (continued)--When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats.
    
17. Second Method--Rotate the crankshaft in the engine rotational direction clockwise until the number 1 piston is at TDC on the compression stroke. The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. A 0.005 inch feeler gauge should not slide under the straight edge (1).
    
18. Use a white paint pen or equivalent to place a reference mark on the harmonic balancer to the front cover for alignment purposes.
19. Lower the vehicle.
Important: If the timing is correct (TDC compression stroke number 1 cylinder), the camshaft flats will be in the up position.
Install J 44221 to the back of the camshafts.

20. Remove the upper timing chain guide to the cylinder head.
    
21. Clean the timing chain and gears with brake cleaner or suitable solvent. Use a white paint pen or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. It is recommended that the paint marks be in the 12 o'clock position.


22. Install EN-48464 . It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt.



23. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain.
24. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer. The wedge tool will be fully seated against the tensioner after it moves about 25 mm (1 in).
25. Once the tool is correctly installed, unscrew the handle and remove the handle


26. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
27. Remove the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
28. Remove both upper timing chain tensioner shoe bolts.
29. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.



30. Carefully remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts. The illustration shows the exhaust camshaft sprocket already removed.



31. Remove the sprockets from the chain, tie a piece of mechanic's wire on the timing chain and let it drop.



32. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. If a bolt breaks during engine disassembly, EN-47702 is available to assist in the removal of the remaining bolt segment.
    
33. Remove the cylinder head bolts. Discard the bolts.
    
34. Remove the cylinder head.
35. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
    
36. Remove the cylinder head gasket.
Discard the gasket.

37. Remove all remaining gasket material from the engine block.
38. Inspect the cylinder head gasket mating surface on the engine block.
39. Clean and inspect the cylinder head.
40. Disassemble the cylinder head if necessary.

TDC is an acronym for Top Dead Center. It is when the piston has reached the very top of its travel and there is nowhere for the piston to go but down. If you align the timing marks on the engine, the piston will be at TDC with the valves on #1 closed.

To position your crankshaft and cam to the correct position, it should be done BEFORE removing the belt if possible. If the belt has already been removed and/or the belt was broken, the same principles apply, but you will have to go about it completely different.

Turn the engine clockwise to align the "O" on the crankshaft pulley with the "O" on the outer timing belt cover.
Remove the plug in the outer timing belt cover and look through the hole. The timing marks on the camshaft pulley should align with the cover pointer. If they do not align, rotate the crankshaft one full revolution and align the "Os" again. They should now align. When every thing is lined up like this, your engine is timed to #1 at TDC and the valves on #1 cylinder will be closed.

Now if the belt has already been removed or if the belt was broken, You may have to temporarily put the outer cover back on. You may have to put it on and take it off several times until you get things lined up. Time the crankshaft "Os" first. It will not matter which rotation you are on if the belt is not installed. (TDC is TDC - the piston doesn't really care where the valves are - that's the camshaft's problem LOL)
After the crank shaft is lined up, turn the camshaft so the timing marks line up with the pointer. Then remove the front cover and install your belt.

After setting the timing belt tensioner, rotate the engine two full turns clockwise and recheck to make sure that all the timing marks still line up. If they do not - repeat the procedure.

This is the complete procedure from the service manual on how to replace the timing belt start to finish, start over to assure u get it right, if u mess up the engine will be damaged

Removal for 1.6L engines : ONLY 2006 to 2009 CARS


Engine removal is not required for this procedure.

1.Remove the engine cover.

2.Remove the RH front wheel.

3.Remove the 2 bolts and RH side cover.

4.Temporarily loosen the water pump pulley bolts.

5.Remove the alternator drive belt

6.Remove the air conditioner compressor drive belt

7.Remove the power steering pump drive belt

8.Remove the 4 bolts and water pump pulley.

9.Remove the 4 bolts and timing belt upper cover

10.Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing belt cover. Check that the timing mark of camshaft sprocket is aligned with the timing mark of cylinder head cover. (No.1 cylinder compression TDC position)

11.Remove the crankshaft pulley bolt and crankshaft pulley

12.Remove the crankshaft flange

13.Remove the 4 bolts and timing belt lower cover

14.Remove the timing belt tensioner and timing belt.

15.Remove the bolt and timing belt idler

16.Remove the crankshaft sprocket

17.Remove the cylinder head cover.

(1)Remove the wire harness bracket

(2)Remove the ignition coil.

(3)Remove the PCV (Positive Crankcase Ventilation) hose and the breather hose from the cylinder head cover

(4)Remove the engine cover bracket

(5)Loosen the cylinder head cover bolts and then remove the cover and gasket.

18.Remove the camshaft sprocket.

Hold the portion of the camshaft with a hexagonal wrench, and remove the bolt with a wrench and remove the camshaft sprocket.

INSTALLATION:

1.Install the camshaft sprocket and tighten the bolt to the specified torque.

(1)Temporarily install the camshaft sprocket bolt

(2)Hold the portion of the camshaft with a hexagonal wrench, and tighten the bolt with a wrench
Tightening torque :78.5 ~ 98.1N.m (8.0 ~ 10.0kgf.m, 57.9 ~ 72.3lb-ft)



2.Install the cylinder head cover.

(1)Install the cylinder head cover and bolts
Tightening torque :7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

(2)Install the engine cover bracket

(3)Install the PCV(Positive Crankcase Ventilation) hose and breather hose to the cylinder head cover.

(4)Install the ignition coil.

3.Install the crankshaft sprocket

4.Align the timing marks of the camshaft sprocket and crankshaft sprocket with the No.1 piston placed at top dead center and its compression stroke.

5.Install the idler pulley and tighten the bolt to the specified torque.

Tightening torque :42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)

6.Temporarily install the timing belt tensioner

7.Install the belt so as not give slack at each center of shaft. Use the following order when installing timing belt.
Crankshaft sprocket →idler pulley →camshaft sprocket →timing belt tensioner

8.Adjust the timing belt tension.

(1)Loosen the tensioner pulley mounting bolt and apply tension to the timing belt.

(2)After checking the alignment between each sprocket and each timing belt tooth, tighten the mounting bolt and one by one.

Tightening torque :19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

(3)Then recheck the belt tension.
Verify that when the tensioner and the tension side of the timing belt are pushed in horizontally with a moderate force [approx. 49N (11lb)], the timing belt cog end is aprox. 1/2 of the tensioner mounting bolt head radius (across flats) away from the bolt head center.

4)Timing belt tension measuring procedure
(by a sonic tension guage)
Rotate crankshaft in clockwise direction to set 1st piston on top dead center (TDC) and rotate crankshaft in counterclockwise to 90° then measure the belt tension in the middle of tension side span (in arrow direction of above illustration) by free vibration method.


9.Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and camshaft sprocket timing mark.


10.Install the timing belt lower cover with 5bolts

Tightening torque :7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

11.Install the flange and crankshaft pulley, and then tighten crankshaft pulley bolt. Make sure that crankshaft sprocket pin fits the small hole in the pulley.

Tightening torque :137.3 ~ 147.1N.m (14.0 ~ 15.0kgf.m, 101.3 ~ 108.5lb-ft)

12.Install the timing belt upper cover with 4 bolts.

Tightening torque :7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

13.Install the water pump pulley and 4 bolts.

14.Install the power steering pump drive belt

15.Install the air conditioner compressor drive belt

16.Install the alternator drive belt

17.Install the RH side cover with 2 bolts

18.Install the RH front wheel.


Tightening torque :88.3 ~ 98.1N.m (9.0 ~ 10.0kgf.m, 65.1 ~ 72.3lb-ft)

19.Install the engine cover with bolts.


Tightening torque :3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

firing order 1-4-2-5-3-6

1. Insert each ignition wire on proper terminal of distributor cap . Ensure ignition wires are properly seated on the terminals. The No. 1 terminal is identified on distributor cap .

not sure if #1 cylinder is on the front right or front left. Call a dealer.

Installation
Before installing distributor , visually inspect distributor . Inspect the O-ring. It should fit tightly and be free of cuts. The drive gear should be free of nicks, cracks and excessive wear. Rotate distributor drive shaft. It should move freely, without binding.

1. To install distributor correctly, No. 1 piston (6108) must be at Top Dead Center (TDC) of compression stroke. Remove No. 1 cylinder spark plug (12405) and rotate crankshaft (6303) clockwise until No. 1 piston is on the compression stroke.

1. With No. 1 piston on compression stroke, align timing pointer with TDC on the crankshaft damper.

1. Align locating boss on distributor rotor with hole on armature. Fully seat distributor rotor on distributor shaft.

1. Rotate distributor shaft so blade on distributor rotor is pointing toward mark on distributor base that was previously made in Step 2 of the Removal procedure.

1. While installing, continue rotating distributor rotor slightly so leading edge of the vane is centered in vane switch stator assembly.

1. Rotate distributor in engine front cover to align leading edge of vane and vane switch stator assembly. Verify distributor rotor is pointing at No. 1 mark on distributor base. If vane and vane switch stator cannot be aligned by rotating distributor in engine front cover , remove distributor enough to just disengage distributor gear from camshaft gear. Rotate distributor rotor enough to engage distributor gear on another tooth of camshaft gear. Repeat Step 1 if necessary.
   

1. Install distributor hold-down clamp and bolt. Tighten bolt, but leave it loose enough to rotate distributor .

1. Install distributor cap , No. 1 spark plug and ignition wires. Check that ignition wires are securely connected to the distributor cap and spark plugs . Tighten distributor cap hold-down screws to 2.0-2.6 Nm (18-23 lb-in).

1. Reconnect distributor to engine control sensor wiring .

1. Set initial engine ignition timing according to procedures found in Section 8A of the Powertrain Control/Emissions Diagnosis Manual.

1. After engine ignition timing is set, tighten distributor hold-down bolt on to 20-30 Nm (15-22 lb-ft).

1. Recheck initial engine ignition timing. Adjust if necessary.