Timing chain marks and install - 2007 Toyota Yaris

wow no job stated.
04 (2.3L) ill take a wild guess and say, you might be fiddling the cam
and doing something there, new cam, new lifters, new chain, new head, ? what?
FSM means factory service manual, ever heard of one?

the FSM is just lousy 4 bucks why not read that first. and not mess it up.

https://suzukipitstopplus.com/Products/1004-2004-aerio-service-manual.aspx

you said SET, so i can only assume its all apart. right then
you want to Instal the chain and time it, right so here are the fsm steps
no photos. log in and read the FSM for that.

1. Check that match mark on crankshaft timing sprocket is in match with timing mark on lower crankcase.
2. Install crankshaft timing sprocket as shown in figure.
3. Apply oil to bush of idler sprocket and install idler sprocket and sprocket shaft.
4. Install first timing chain by aligning dark blue plate of first timing chain and match mark on idler sprocket.
5. Bring yellow plate of first timing chain into match with match mark on crankshaft timing sprocket.
6. Apply engine oil to sliding surface of timing chain tensioner and then install it as shown in figure. Tighten tensioner nut to 18 ft. lbs. (25 Nm).
7. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch and body. After inserting it, check to make sure that plunger will not come out.
8. Install timing chain tensioner adjuster No.1. Tighten the timing chain tensioner adjuster No. 1 bolt to 8 ft. lbs. (11 Nm).
9. Pull out stopper from adjuster No.1.
10. Apply engine oil to sliding surface of timing chain guide No.1 and then install it. Tighten guide bolts to 6.5 ft. lbs. (9 Nm).
11. Check that dark blue and yellow plates of first timing chain are in match with match marks on sprockets respectively.
12. Install second timing chain as follows:
    • Check that match mark on crank timing sprocket is in match with timing mark on lower crankcase.
    • Check that arrow mark on idler sprocket faces upward.
    • Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head.
    • Install second timing chain by aligning yellow plate of second timing chain and match marks on idler sprocket.
    • Install sprockets to intake and exhaust camshafts by aligning dark blue plate of second timing chain, match marks on intake sprocket and exhaust sprocket respectively. NOTE As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.
      
      
      

• Install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary. Tighten the camshaft timing sprocket bolt to 57.5 ft. lbs. (80 Nm).
• Push back plunger into tensioner body and hold it at the position by inserting stopper into body.
• Install timing chain tensioner adjuster No.2 with new gasket. Tighten the timing chain tensioner adjuster No. 2 bolts to 8 ft. lbs. (11 Nm) and No. 2 nut to 33 ft. lbs. (45 Nm).
• Pull out stopper from timing chain tensioner adjuster No.2.
• Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block.
• Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
• Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
• Install timing chain cover. Reverse removal sequence to install timing chain cover noting the following points:
  
  • Apply sealant "A" and "B" to area as shown.
    
    • "A": Sealant 99000-31250
    • "B": Sealant 99000-31140
  • Apply sealant amount to the following areas.
    
    • "a": 0.12 inches (3mm)
    • "b": 0.08 inches (2mm)
    • "c": 0.24 inches (6mm)
    • "d": 0.63 inches (16mm)
    • "e": 0.55 inches (14mm)
    • "f": 2.56 inches (65mm)
    • "g": 2.87 inches (73mm)
    • "h": 0.16 inches (4mm)
  • Apply engine oil to oil seal lip, then install timing chain cover. Tighten bolts and nut to 8 ft. lbs. (11 Nm).
    NOTE Before installing timing chain cover, check that pin is securely fitted.
• • Before installing timing chain cover, check that pin is securely fitted.
• Install alternator belt idler pulley. Tighten nut to 30.5 ft. lbs. (42 Nm).
• Install alternator belt tensioner. Tighten bolts to 18.5 ft. lbs. (25 Nm).
• Install water pump pulley.
• Install A/C compressor bracket (if equipped). Tighten bracket bolts to 40 ft. lbs. (55 Nm).
• Install cylinder head cover with new gaskets and seal washers and tighten nuts to 8 ft. lbs. (11 Nm).
• Install oil pan.
• Install crankshaft pulley using pulley holder tool. Tighten the crankshaft pulley bolt to 108.5 ft. lbs. (150 Nm).
• Install engine assembly.
• Install all remaining components in the reverse order of the removal procedure.

did that cover it, surely not.
but if you get the FSM and read it or log in , you will not miss the photos and the complex sealing bs on this motor.

alldata dot com has a that , as does mitchels and chilton online.
http://www.fixkick.com/look/v6/6v-chain-marks.jpg

Removal & Installation

3.5L Engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Record the radio anti theft code data.
3. Remove or disconnect the following:
   
   Negative battery cable Engine cover Accessory drive belts Idler pulley Crankshaft pulley Power steering pump pulley Belt tensioner pulley Upper and lower timing belt covers
   
4. Support the engine with a floor jack and remove the engine mount.
5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.
   
   

   Fig. Timing belt routing and timing marks-3.5L Engine
   

6. Remove or disconnect the following:
   
   Auto tensioner Timing belt
   
   

   Fig. Timing belt and related components-3.5L Engine
   
   

To install:

1. Ensure that the engine is set to Top Dead Center (TDC).
2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
3. Install the timing belt in the following order:
   1. Crankshaft sprocket
   2. Idler pulley
   3. Left bank exhaust camshaft sprocket
   4. Left bank intake camshaft sprocket
   5. Water pump pulley
   6. Right bank intake camshaft sprocket
   7. Right bank exhaust camshaft sprocket
   8. Tensioner pulley
   
   
4. Install the auto tensioner. Do not remove the retaining pin at this time.
5. Check that the crankshaft and camshaft timing marks are aligned correctly.
6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
8. Loosen the tensioner pulley center bolt.
9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).
   
   

   Fig. Adjusting the tensioner pulley-3.5L Engine
   

10. Remove the auto tensioner retaining pin.
11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.
    
    

    Fig. Measuring the auto tensioner rod-3.5L Engine
    

13. When the auto tensioner measurement is correct, install or connect the following:
    
    Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable
    
14. Reprogram the radio anti theft codes.

    Kia_Sedona_2002-2006
    Timing Chain, Sprockets, Front Cover & Seal

    • REMOVAL & INSTALLATION

    Print
    

    
    Removal & Installation
    
    3.8L Engine
    

    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Record the radio anti theft code data.
    3. Remove the engine from the vehicle.
    4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
    5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
    6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
    7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
    10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
    11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
        NOTE Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
        
    12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
    13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
    14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
    15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
    16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.
        
        

        Fig. Timing chain and related components-3.8L Engine
        

    
    To install:
    
    1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
    2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
    3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
    4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
    5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
    6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
    7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
       
       

       Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine
       

    8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
    9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
    10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
    11. Install the crankshaft sprocket, oil pump and right camshaft drive.
    12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
    13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
    14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
        
        

        Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine
        

    15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
    16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
    17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
    18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
    19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
    20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
    21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
    22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
        NOTE Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Sealant application (1 inch bead width)-3.8L Engine
        

    23. Apply sealant on the chain cover.
        NOTE The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Timing cover sealant application-3.8L Engine
        

    24. Install a new gasket to the timing case cover.
        NOTE It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.
        
        
        

        Fig. Timing cover gasket installation (A) gaskets-3.8L Engine
        

    25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.
        
        

        Fig. Timing cover bolt torque sequence and specification-3.8L Engine
        

    26. Install the timing case cover oil seal.
    27. Continue the installation in the reverse order of the removal procedure.

Here you go This will help you

Hi, this engine user copper links on the chain align the copper links with the marks shown on the diagram below. Please let me know if you have more questions, and thanks for using FixYa.

To install:

1. Compress the timing chain tensioner plunger in a soft jaw vise and install a retaining clip to hold the plunger in place.
2. Remove the tensioner.
3. If the copper links are not visible on the timing chains, mark one link on each end of the chain.
4. Install the left and right timing chain guides and tighten the bolts to 89 inch lbs. (10 Nm).
5. Position the lower end of the left timing chain on the crankshaft sprocket, aligning the copper link with the timing mark on the outer flange of the crankshaft sprocket.
6. Position the timing chain on the left camshaft sprocket with the camshaft sprocket timing mark aligned with the copper link.
7. Position the left timing chain tensioner arm on the dowel pin and install the timing chain tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
8. Remove the retaining clip from the tensioner plunger.
9. Position the lower end of the right timing chain on the crankshaft sprocket, aligning the copper link with the timing mark on the outer flange of the crankshaft sprocket.
10. Position the timing chain on the right camshaft sprocket with the camshaft sprocket timing mark aligned with the copper link.
11. Position the left timing chain tensioner arm on the dowel pin and install the timing chain tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
12. Remove the retaining clip from the tensioner plunger.
13. Ensure correct alignment of all timing chain links and sprocket timing marks.
14. Install the camshaft roller followers and tighten the camshaft sprocket bolts. See the procedure under Camshaft.
15. Install the crankshaft sensor ring on the crankshaft.
    
    
    

    Fig. Timing chain link and sprocket timing mark alignment-4.6L engine
    

16. Apply sealant to the front cover mating surface as shown.
    
    
    

    Fig. Sealant application to the front cover mating surface-4.6L engine
    

17. Install a new gasket on the front cover, then install the front cover and hand tighten the bolts.
18. Tighten the front cover bolts in the sequence shown to 18 ft. lbs. (25 Nm).
19. Tighten the front cover-to-oil pan bolts in the sequence shown to 15 ft. lbs. (20 Nm), plus an additional 60 degrees
    
    
    

    Fig. Front cover bolt tightening sequence-4.6L engine
    
    
    
    

    Fig. Front cover-to-oil pan bolt tightening sequence-4.6L engine
    

20. Lubricate the engine front cover and oil seal lip with clean engine oil and install the seal using a seal installer.
21. Apply sealant to the Woodruff key slot in the crankshaft pulley, then press on the crankshaft damper.
22. Tighten the crankshaft damper as follows:
    1. Step 1: 66 ft. lbs. (90 Nm).
    2. Step 2: Loosen the bolt one full turn.
    3. Step 3: 37 ft. lbs. (50 Nm).
    4. Step 4: 90 degrees.
    
    
23. Connect the crankshaft position sensor connector.
24. Install the power steering pump and tighten the bolts to 18 ft. lbs. (25 Nm).
25. Install the wiring harness retainer to the power steering stud bolt.
26. Install the power steering pump pulley shield.
27. Install the water pump pulley.
28. Install the J bracket to the engine front cover stud bolt.
29. Install both left and right camshaft position sensor connectors.
30. Install both left and right radio interference capacitors.
31. Connect the hoses from the coolant crossover.
32. Install the valve covers. See the procedure under Cylinder Head.
33. Install the right side idler pulley.
34. Install the accessory drive belt.
35. Install the coolant degas bottle.
36. Connect the negative battery cable.
37. Fill the crankcase with clean engine oil.
38. Start the engine. Check for leaks and proper operation.

Timing Chain and Gears REMOVAL & INSTALLATION 1.9L Engine NOTE: The following procedure requires the use of the puller tool No. J-25031 or equivalent, and timing sprocket installation tool No. J-26587 or equivalent.

1. Remove the timing (front) cover from the engine.
2. Lock the shoe on the automatic adjuster in fully retracted position by depressing the adjuster lock lever. NOTE: To remove the timing chain, it may be necessary to remove the camshaft sprocket. Before removing the timing chain, be sure to align the timing marks.
   
3. Remove timing chain from crankshaft sprocket.
4. Check the timing sprockets for wear or damage. If crankshaft sprocket must be replaced, remove the sprocket and the pinion gear from crankshaft using the puller tool No. J-25031 or equivalent.
5. Check timing chain for wear or damage; replace as necessary. Measure distance "L'' (40 links) with the chain stretched with a pull of approximately 22 lbs. (98N). Standard "L'' value is 15 in. (381mm); replace chain if "L'' is greater than 15.16 in. (385mm).
6. Remove the automatic chain adjuster-to-engine bolt and the adjuster.
7. To check the operation of the automatic chain adjuster, push the shoe inwards, if it becomes locked, the adjuster is working properly. The adjuster assembly must be replaced if rack teeth are found to be worn excessively.
8. To remove the chain tensioner, remove the "E'' clip and the tensioner. Check the tensioner for wear or damage; if necessary, replace it. Fig. 1: Timing chain guide and tensioner - 1.9L engine
   
   
9. Inspect the tensioner pin for wear or damage. If replacement is necessary, remove the pin from the cylinder block using a pair of locking pliers. Lubricate the NEW pin tensioner with clean engine oil. Start the pin into block, then place the tensioner over the appropriate pin. Position the E-clip onto the pin, then (using a hammer) tap it into the block until clip just clears tensioner. Check the tensioner and adjuster for freedom of rotation on the pins.
10. Inspect the guide for wear or damage and plugged lower oil jet. If replacement or cleaning is necessary, remove the guide bolts, the guide and the oil jet. Install a new guide and upper attaching bolt. Install the lower oil jet and bolt, so that the oil port is pointed toward crankshaft. To install: Fig. 2: Timing chain alignment and installation - 1.9L engine
    Fig. 3: Inspecting the timing chain for wear
    
    
11. Install the timing sprocket and the pinion gear (groove-side toward the front cover). Align the key groove with crankshaft key, then drive it into position using installation tool No. J-26587 or equivalent.
12. Turn the crankshaft so that key is turned toward the cylinder head-side (No. 1 and No. 4 pistons at TDC).
13. Install the timing chain, align the timing chain mark plate with the mark on the crankshaft timing sprocket. The side of the chain with the mark plate is on the front-side and the side of chain with the most links between mark plates is on the chain guide-side. Keep the timing chain engaged with the camshaft timing sprocket until the camshaft timing sprocket is installed on the camshaft.
14. Install the camshaft timing sprocket so that it's marked-side faces forward and it's triangular mark aligns with the chain mark plate.
15. Install the automatic chain adjuster.
16. Release the lock by depressing the shoe on adjuster by hand, and check to make certain the chain is properly tensioned when the lock is released.
17. Install the timing cover assembly.

To Install:

1. Install balance shaft drive gear onto the left camshaft.
2. Install the camshaft sprockets and new bolts finger tight.
3. Using a vise, compress the timing chain tensioner plunger.

4. Install a retaining clip on the tensioner to hold plunger IN during installation.
   marking timing chain
   

5. If timing chain copper links are not visible, mark 2 links on one end and 1 link on the other end to be used as timing marks.
6. Install right and left timing chain guides. Tighten bolts to 89 in-lbs (10 Nm).
7. Rotate the left camshaft until the timing mark is at the 12 o'clock position.
8. Rotate the right camshaft until the timing mark is at the 11 o'clock position.

9. Position the crankshaft using the special tool. Then remove the tool.
   Crankshaft special tool positioning
   

10. Install the crankshaft sprocket with flange facing forward.
    Crankshaft sprocket timing mark
    

11. Position lower end of left (inner) timing chain on the crankshaft sprocket. Align the copper (or marked) chain link with the timing mark on the outer flange of the crankshaft pulley. NOTE: Upper half of timing chain must be below the tensioner arm dowel.
    

12. Position the left timing chain on the camshaft sprocket. The timing mark on the camshaft sprocket must be aligned between the 2 copper (or marked) chain links.
    Left camshaft sprocket timing mark
    

13. Place the left timing chain tensioner arm on the dowel pin and install the timing chain tensioner and bolts. Tighten bolts to 18 ft-lbs (25 Nm). NOTE: Lower half of timing chain must be above the tensioner arm dowel.
    Crankshaft sprocket timing mark
    

14. Position lower end of right (outer) timing chain on the crankshaft sprocket. Align the copper (or marked) chain link with the timing mark on the outer flange of the crankshaft pulley.
    Right camshaft sprocket timing mark
    

15. Position the right timing chain on the camshaft sprocket. The timing mark on the camshaft sprocket must be aligned between the 2 copper (or marked) chain links.
16. Place the right timing chain tensioner arm on the dowel pin and install the timing chain tensioner and bolts. Tighten bolts to 18 ft-lbs (25 Nm).
17. Remove the retaining clips from the right and left timing chain tensioners.
18. Verify alignment of all timing marks.
19. Install crankshaft sensor ring on crankshaft.
20. Locate index mark on balance shaft and mark corresponding gear tooth with chalk.
21. Position balance shaft on journals. NOTE: It may be helpful to use an inspection mirror to view the marks timing marks.
    

22. Align the chalk mark on the balance shaft with the camshaft timing mark.
    Balance shaft bearing caps
    

23. Install the balance shaft bearing caps in their original locations. Follow the tightening sequence as shown in the illustration. Tighten bolts to 89 in-lbs (10 Nm).
24. Tighten the camshaft phaser sprocket bolts in the correct sequence using 2 steps, as follows:
    • Step 1-30 ft-lbs (40 Nm)
    • Step 2-tighten an additional 90 degrees
25. Position the crankshaft keyway in the 11 o'clock position.
26. Lubricate and install all camshaft roller followers. WARNING
    Engine front cover replacement procedure must be completed within 4 minutes or entire procedure must be repeated. Failure to do so may result in future leaks
    

check around the inside (towards the block) edge or crank shaft pulley by the lower passenger side of the engine. Otherwise it will be by that pulley on the bloc, those are the only laces I've known them to be. Hope it helps

.

1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.

1. Remove the crankshaft sensor ring from the crankshaft.

1. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.

1. Using the special tool, position the crankshaft as shown.
   

1. Install the special tool.

1. NOTE: LH shown; RH similar.
   Remove the two bolts, the timing chain tensioner and tensioner arm.

1. Remove the LH and RH timing chains and the crankshaft sprockets.
   
   • Remove the special tool from the crankshaft.
   • Remove the timing chains from the camshaft sprockets.
   • Remove the right and left timing chains and the crankshaft sprocket from the crankshaft.

1. CAUTION: The bolts are different lengths and must be returned to their original location.
   NOTE: LH shown; RH similar.
   Remove the bolts and the timing chain guides.

Installation

1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
   CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
   Compress the tensioner plunger, using an edge of a vise.

1. Using a small screwdriver or pick, push back and hold the ratchet mechanism.

1. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

1. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.

1. Remove the tensioner from the vise.

1. NOTE: There are 61 links in the timing chain.
   If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.

1. Install the timing chain guides.

1. Using the special tool, verify correct crankshaft position.
   • Remove the special tool.

1. NOTE: Crankshaft sprockets are identical. They can only be installed one way. Refer to the following illustration for correct crankshaft sprocket installation.
   If removed, install LH and RH crankshaft sprockets.

1. Install the LH timing chain onto the crankshaft sprocket, aligning the one copper (marked) link on the timing chain with the slot on the crankshaft sprocket.

1. Position the LH timing chain on the camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.

1. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

1. Position the RH timing chain on the camshaft sprocket. Make sure the two copper (marked) links align with the camshaft sprocket timing mark.

1. NOTE: LH shown; RH similar.
   Position the tensioner arms and tensioners, and install the bolts.

1. Remove the tensioner retaining clip.

1. As a post-check, verify correct alignment of all timing marks.

1. Remove the special tool.

1. Position the crankshaft sensor ring on the crankshaft.

1. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.

Except Premier
Procedures applying to removal and installation of the auxiliary shaft drive chains are located under Auxiliary (Intermediate or Silent) Shafts Removal and Installation, later in this section.
2.5L Premier Engine (See Figures 1 through 5)

Fig. 1: To remove the timing chain, remove the timing chain case cover

Fig. 2: When removing and installing the timing chain the crankshaft and camshaft sprocket timing marks should be aligned as shown

Fig. 3: While holding the timing chain, camshaft sprocket and crankshaft sprocket aligned install them onto the engine


Fig. 4: Lock and unlock the timing chain tensioner by switching the tensioner lever, as shown


Fig. 5: To verify correct installation, turn the crankshaft until the camshaft sprocket timing mark is approximately at the one o'clock position, then count the number of chain link pins between the points shown

1. Disconnect the negative battery cable.
2. Remove the fan shroud and cooling fan, as described earlier in this section.
3. Remove the accessory drive belts. For more information, refer to .
4. Remove the water pump pulley and crankshaft vibration damper, as described earlier in this section.
5. Remove the timing case cover, as described previously in this section.

It is a good practice to either remove or cover the radiator area when performing extensive repairs to the engine to prevent accidental damage to the radiator core.

1. Rotate the crankshaft until the 0 timing mark on the crankshaft sprocket is closest to and on a center line with the timing mark on the camshaft sprocket.
2. Remove the oil slinger from the crankshaft.
3. Remove the camshaft retaining bolt and remove the sprockets and chain as an assembly.
4. If the timing chain tensioner is to be replaced, the oil pan must also be removed.

To install:

1. Turn the tensioner lever to the unlock (down) position and pull the tensioner block toward the tensioner lever to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position.
2. Install the crankshaft sprocket, camshaft sprocket and timing chain together. Make sure the timing marks are aligned as indicated in Step 6 and in the accompanying illustration.
3. Install the camshaft sprocket retaining bolt and washer. Tighten the bolt to 80 ft. lbs. (108 Nm).
4. To verify correct installation of the timing chain, rotate the crankshaft until the camshaft sprocket timing mark is approximately at the 1 o'clock position. Count the number of chain link pins between the camshaft timing mark and the crankshaft timing mark, there should be 20 pins (2 per link) between the marks.
5. Make sure that the timing chain tensioner switches to the unlocked position. If the tensioner does not switch automatically unlock, switch it manually to the unlock position.
6. Install the oil slinger.
7. Install the timing case cover, as described earlier in this section.
8. Install the water pump pulley and crankshaft vibration damper, as described earlier in this section.
9. Install and properly tension the accessory drive belts. For more information, refer to .
10. Install the fan shroud and cooling fan, as described earlier in this section.
11. Connect the negative battery cable, start the engine and check for leaks.

Good luck... and remember rated this help.