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SERVICE INFORMATION A revised service procedure for the engine front cover/timing chain has been adopted for the GA16DE. It is no longer recommended to remove the cylinder head when removing the timing chain/front cover(s). Utilize the following steps when servicing the front cover, timing chain, guides or tensioner(s) PARTS INFORMATION Caution ^ After removing the timing chain, do not turn the crankshaft and camshaft separately or the valves will strike the piston heads. ^ When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil. ^ Apply new engine oil to bolt threads and seat surfaces when installing the camshaft sprockets and the crankshaft pulley. ^ Do not spill engine coolant on the drive belts. ^ Please refer to the Service Manual for the correct tightening torque. Removal 1. Set # 1 piston at TDC on its compression stroke. 2. Remove the spark plug wires. 3. 4. Remove the rocker cover (see Figure 1). Remove the coolant reservoir tank with bracket and reposition it for clearance. 5. Support the engine with a suitable jack. 6. Remove cylinder head front mounting bracket. 7. Remove engine front mounting, then the engine front mounting bracket. 8. Remove cylinder head front cover. 9. Remove the upper chain tensioner (see Figure 2). 10. Wipe off the links of the upper timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with the timing marks on the cam sprockets and idler sprocket (see Figure 3) 11. Remove the four (4) front cover to cylinder head bolts. 12. Remove side and lower engine compartment splash covers. 13. Remove the accessory drive belts. 14. Remove the crankshaft pulley. 15. Drain coolant by removing the cylinder block drain plug and opening the radiator drain cock (Refer to MA section of the Service Manual). 16. Drain engine oil. 17. Remove intake manifold support of engine front side. 18. Remove power steering pump, pump bracket and tension rod. Position pump aside for clearance.

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The above application is prone to the timing belt teeth lifting off the belt in service due to operating the belt with insufficient tension. The following instructions have been produced to assist in the fitting of your new timing belt, giving simple hints and tips, which should help avoid problems caused by adopting an incorrect fitting / adjustment procedure. For instructions for the removal of the engine components required to gain access to the timing belt, please refer to the vehicle workshop manual. Note:- Incorrect tension of the timing belt, can lead to the teeth lifting from the belt, resulting in belt failure, and subsequent major engine damage. Special Tools Required: 1) Timing belt tension gauge, (accurately calibrated), Part No’s: either Rover KM4088 or Borroughs BT33-86F 2) Two 8mm Allen keys (for tensioner adjustment) 3) Short length of round steel bar (for flywheel timing location) Fitting Procedure: 1) Before the old timing belt is removed, the crankshaft should be rotated clockwise to align the timing mark on the crankshaft pulley with the edge of the metal bracket, which forms part of the lower timing belt cover (See I). To lock the crankshaft in this position, which is 90 degrees before top dead centre, insert a steel rod of the correct diameter into the hole on the gearbox / engine adaptor plate, positioned on the front facing lower edge of the cylinder block (See diagram B), and locate with the corresponding hole in the flywheel. The timing marks on the camshaft gears should now be aligned at the 3 o’clock position for the left hand gear, and the 9 o’clock position for the right hand gear (See II). Undo the timing belt tensioner Allen bolt and remove tensioner. The old timing belt can now be removed (See III). Check the condition of the geared teeth on the camshaft, crankshaft, and water pump drives. Check the tensioner, water pump, and idler bearings. Fit the new timing belt over the drive gears, ensuring the timing marks set at ‘I’and‘II’ have not moved. Refit the tensioner using the anti-slip washer ‘IV’ supplied with the new timing belt. The anti-slip washer should be fitted between the tensioner and the backplate, with the abrasive side facing towards the tensioner. Note: A new anti-slip washer must always be fitted. Non modified vehicles will not have the anti-slip washer fitted. Rotate the tensioner, using the Allen key drive to set the initial pre-load tension, sufficient to prevent the timing belt from slipping over the toothed drives, then tighten the Allen bolt to 45Nm.

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CAUTION: Since the engine is not free wheeling if the crankshaft (6303) or the camshafts (6250) are moved in any manner during removal and installation the crankshaft and camshafts must be resynchronized. These steps are located in Engine Assembly Steps 36 to 48. 1. Remove the engine front cover (6019); refer to Engine Front Cover — 5.4L in this section. 2. Remove the crankshaft sensor ring from the crankshaft. 3. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. Position the crankshaft with the Crankshaft Holding Tool as shown. 4. Install and fully tighten the Camshaft Holding Tools on both camshafts. 5. Remove the timing chain tensioning system from both timing chain/belts (6268). 1. Remove the bolts. 2. Remove the timing chain tensioners (6L266). 3. Remove the timing chain tensioner arms (6L253). 6. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur. CAUTION: Do not remove the Camshaft Holding Tool. Remove the LH and RH timing chains and the crankshaft sprockets (6306). ? Remove the Crankshaft Holding Tool. ? Remove the RH timing chain from the camshaft sprocket. ? Remove the RH timing chain and outer crankshaft sprocket from the crankshaft. ? Repeat for the LH timing chain and crankshaft sprocket. 7. Remove both timing chain guides (6K297). ? Remove the bolts. ? Remove both timing chain guides. 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. 2. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

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CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur. 1. Remove the engine front cover. For additional information, refer to Engine Front Cover—4.6L in this section. 2. Remove the crankshaft sensor ring from the crankshaft. 3. 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. 4. Install the special tools on the camshaft. 5. Remove the timing chain tensioning system from both timing chains. 1. Remove the bolts. 2. Remove the timing chain tensioners. 3. Remove the timing chain tensioner arms. 6. Remove the timing chains and the crankshaft sprockets. 7. Remove the timing chain guides. 1. Remove the bolts. 2. Remove the LH timing chain guide. 3. Remove the bolts. 4. Remove the RH timing chain guide. Installation 1. CAUTION: The 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.

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CAUTION: Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage can occur. 1. Remove the engine front cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. 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. 4. Install the special tools on the camshaft. 5. Remove the timing chain tensioning system from both timing chains. 1 Remove the bolts. 2 Remove the timing chain tensioners. 3 Remove the timing chain tensioner arms. 6. Remove the timing chains and crankshaft sprocket. 7. Remove the timing chain guides. 1 Remove the bolts. 2 Remove the LH timing chain guide. 3 Remove the bolts. 4 Remove the RH timing chain guide. Installation