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Tech Talk
Alloytec Timing Chain
Timing Chain
VZ – VE Commodore Alloytec 3.6 Litre The timing for this engine is carried out in two stages. It is important that you read all the instructions before commencing the job, especially the Notes and Cautions.
Warning! Retiming this engine requires the use of camshaft alignment tools EN 46105-1 and EN 46105-2. Do not attempt to carry this job unless you have these tools.
Timing Chain Removal 1. Disconnect battery earth lead. 2. Remove engine cover. 3. Remove air cleaner assembly and intake duct. 4. Disconnect crankcase ventilation and evap hoses. 5. Disconnect Inlet Manifold Runner Control and throttle plate wiring, remove upper intake manifold. 6. Remove the engine cover mounting bracket.
Note! DO NOT turn crankshaft or camshafts while timing chains are removed unless otherwise stated.
Note:
Disconnect battery before starting work.
8. Remove rocker covers.
Cover coil holes to ensure that no particles inadvertently fall into engine.
Remove spark plugs to ease turning the engine.
9. Drain cooling system. Remove upper and lower radiator hoses, coolant bleed and recovery hoses, cooling fans, and drive belt.
Turn engine in normal direction of rotation unless otherwise stated.
10. Remove harmonic balancer from crankshaft.
DO NOT turn engine by camshafts or other pulleys. Follow all tightening torques. Use Special Tools where directed.
2988
7. Remove ignition coils and spark plugs.
11. Unbolt power steering pump reservoir and relocate away from work area without disconnecting hoses. 12. Unbolt air-conditioning compressor and relocate away from work area without disconnecting refrigerant lines.
VACC Tech Talk – September 2009
Tech Talk
Alloytec Timing Chain
13. Remove camshaft position sensors and variable camshaft timing solenoids from engine. 14. Remove timing chain cover. 15. Turn crankshaft clockwise using special tool EN 46111, until the stage one (first) timing marks are aligned. See Diagrams #3 and #4. 16. Install alignment tool EN 46105-1 to the rear of LH camshaft. See Diagrams #1 & #2. You may need to use a spanner on the flat part of the camshafts to get the tool to fit.
Note:
Do not force or hammer the alignment tool onto the camshaft.
Diagram #3 Crankshaft at Stage One Timing Mark
17. Remove the RH timing chain tensioner, taking care not to loose any of the spring loaded components. 18. Remove the RH timing chain. 19. Remove the tensioner for the primary timing chain, taking care not to loose the spring-loaded components, and then remove the primary timing chain.
Diagram #1 EN 46105-1 Shown from rear fitted to LH Camshafts Note: Camshaft Flats are Parallel with Head Diagram #2 EN 46105-1 Shown from front fitted to LH Camshafts
20. Remove the tensioner for the LH timing chain, taking care not to loose spring-loaded components, and then remove the LH timing chain.
Caution:
If you are removing any sprockets, do not mix them up! The LH intermediate sprocket is marked with the letters LB, while the RH intermediate sprocket is marked RB. On both intermediate sprockets the word Front should be visible when installed.
Caution:
The primary camshaft drive chain lower guide is not separately serviceable. If the primary camshaft drive chain lower guide must be replaced, the oil pump must be replaced.
Note:
Check the timing chains to ensure that the chains have shiny or coloured links to enable retiming of the engine. If not you may need to mark the chains before removing. VACC Tech Talk – September 2009
Caution:
The oil pump is not serviceable. Once dissembled the pump must be replaced. Therefore, only disassemble the pump if you wish to confirm your prior diagnosis.
2989
Tech Talk
Alloytec Timing Chain LH Secondary Chain Intake Timing Marks
LH Secondary Chain Exhaust Timing Marks
L
R
IN
Diagram #4 Engine Timing Marks at Stage One Timing Position
EX
R
L
Primary Chain Timing Marks
LH Secondary Chain Intermediate Sprocket Timing Marks
Crankshaft Aligned with Stage One Timing Mark on Oil Pump
2990
Do not remove Primary Lower Chain Guide or dismantle Oil Pump. If required, these must be replaced as an assembly. VACC Tech Talk – September 2009
Tech Talk
Alloytec Timing Chain
Cleaning and Inspection •
Clean gaskets from timing chain cover and inspect for any damage.
•
Carefully clean the engine front cover sealing surfaces. Insert a piece of cardboard between the oil pan front and the oil pump in order to prevent any pieces of old gasket falling into the oil pan.
•
Check timing chain guides and sprockets for wear, gouges, or deformities.
•
Inspect the timing chains for wear and for cracked or loose rollers.
Note:
Diagram #5 Crankshaft at Stage One Timing Mark
Do Not Remove Lower Primary Chain Guide or Dismantle Oil Pump
Due to the tendency for these timing chains to stretch, it is recommended that, unless they have covered relatively few kilometres, they be replaced.
Timing Chain Installation
Note:
Note:
If reusing the chains ensure that they are refitted to their original position, and not swapped left and right. •
Clean and inspect the tensioners for debris, wear, and freedom of movement. Rotate plungers and lock into retracted positions.
•
Ensure that all seals and gaskets are replaced.
The valve timing on this engine is carried out in two stages. Stage 1, where the crankshaft timing mark is at approximately the 23-minute mark, is where the LH secondary chain and then the primary chain are fitted. Stage 2, where the crankshaft timing mark is at approximately the 43-minute mark, is where the RH secondary chain is fitted.
Stage One 1. Turn crankshaft so that the crankshaft timing mark is aligned with the first timing mark using special tool EN 46111. See Diagrams #3 and #4.
Note:
If the engine is still fitted to the vehicle it is best to use a mirror to check timing mark alignment. 2. Install alignment tool EN 46105-1 to the rear of LH camshaft. See Diagrams #1 and #2. Use a spanner on the flat part of the camshafts to get them into the correct position to enable the tool to fit.
Diagram #6 Triangular and Circular Timing Marks correspond with Right And Left VACC Tech Talk – September 2009
3. Turn LH intermediate chain sprocket to the position shown in Diagram #4.
2991
Tech Talk
Alloytec Timing Chain
5. Fit LH chain guides and tensioner.
EX
Stage Two
L
R
1. Turn the crankshaft clockwise until the crankshaft timing mark is aligned with the second timing mark using special tool EN 46111. See Diagrams #8 and #14.
IN
4. Install the LH chain to inner intermediate sprocket, ensuring that the bright plated or marked chain link can be seen through the timing mark hole in the sprocket. Fit the chain over the LH camshaft sprockets, aligning marked links with the circular timing marks (those marked with an ‘L’). R See Diagram #4.
L
Note:
After fitting tensioner, compress it with your hand to ensure that it unlocks the plunger, and applies tension to the chain.
Diagram #7 Primary Chain Tensioner
Diagram #8 Crankshaft at Stage Two Timing Mark 2. Fit the camshaft alignment tool EN 46105-2 to the rear of LH camshaft. Fit the camshaft alignment tool EN 46105-1 to the rear of RH camshaft. See Diagrams #10, #11 and #12. Use a spanner on the flat part of the camshafts to get them into the correct position to enable the tool to fit.
Tensioner plunger must be rotated and compressed till it is locked. Once fitted it must be compressed to release.
3. Install the RH chain to the sprockets, aligning the bright plated or marked chain links with the intermediate sprocket alignment hole and the camshaft sprocket triangular marking (those marked with an ‘R’). See Diagrams #9 and #14.
6. Install primary chain ensuring the stage one timing marks are aligned. The marked links need to align with the triangles on the intermediate sprockets and the dot on the crankshaft sprocket. See Diagrams #4 and #6. 7. Install the primary chain upper guide. 8. Refit the primary chain tensioner. Release the tensioner by pushing it in against spring pressure to unlock the plunger. 9. Remove the camshaft alignment tool EN 46105-1 from the rear of LH camshaft. 2992
Diagram #9 RH Intermediate Sprocket Chain Alignment Marks
VACC Tech Talk – September 2009
Tech Talk
Alloytec Timing Chain
4. Install chain guides and tensioner. This tensioner also needs to be released by pushing it in against spring pressure to unlock the plunger. 5. Recheck that the timing marks are all aligned. See Diagram #14.
Diagram #10 EN 46105-1 Shown from front fitted to RH Camshafts
6. Recheck the chain tensioners, to ensure they are released and are applying spring pressure to the chains. 7. Remove camshaft alignment tools EN 46105-1 and EN 46105-2 from the camshafts. 8. Rotate the crankshaft at least one full turn clockwise, using special tool EN 46111, to ensure that everything moves freely and smoothly. 9. Refit all parts in reverse order of disassembly, using new gaskets and seals.
Note: Diagram #11 EN 46105-1 Shown from rear fitted to RH Camshafts. Note: Camshaft Flats are Parallel with Head.
Two 8 x 1.25mm studs can be fitted to the block, to guide the timing chain cover when refitting. Fit the remaining bolts finger tight before removing the studs and refitting the original bolts. Then tighten cover bolts evenly.
Diagram #13 Special Tools
EN 46111
Diagram #12 EN 46105-2 Shown from rear fitted to LH Camshafts. Note: Camshaft Flats are at an angle. EN 461105 - 1 Special Tools Required are: •
EN 46111 - Crankshaft Turning Tool
•
EN 46105-1/2 - Camshaft Locking Tools
VACC Tech Talk – September 2009
EN 461105 - 2
2993
Tech Talk
Alloytec Timing Chain RH Secondary Chain Intake Timing Marks
RH Secondary Chain Exhaust Timing Marks L
R
L
IN
R
L
IN
R
EX
EX
R
L
RH Secondary Chain Intermediate Sprocket Timing Marks
Crankshaft Aligned with Stage Two Timing Mark on Oil Pump
Diagram #14 Engine Timing Marks at Stage Two Timing Position
2994
VACC Tech Talk – September 2009
Tech Talk 3.6 Alloytec Bolt Tension
Alloytec Timing Chain Notes
Torque
Camshaft Sprocket Bolt
58Nm
Camshaft Cap Bolt
10Nm
Camshaft Intermediate Sprocket Bolt
58Nm
Crankshaft Balancer Bolt
1st Step
100Nm
2nd Step
150 Degrees
Crankshaft Rear Oil Seal Housing
10Nm
Cylinder Head Bolt
M8 1st Step
15Nm
M8 2nd Step
60 Degrees
M11 1st Step
45Nm
M11 2nd Step
Loosen 120 Degrees
M11 3rd Step
30Nm
M11 4th Step
150 Degrees
1st Step
30Nm
2nd Step
75 Degrees
Flywheel Bolts
Heater Inlet/Outlet Pipes
10Nm
Intake Manifold Bolts
23Nm
Timing Chain Cover Bolt
1st Step
20Nm
2nd Step
60 Degrees
Bolt
25Nm
Cover Bolt
13Nm
Left Guide Bolt
13Nm
Tensioner Bolt
23Nm
Upper Guide Bolt
23Nm
Guide Bolt
23Nm
Shoe Bolt
23Nm
Tensioner Bolt
23Nm
Oil Pump
Primary Chain
Secondary Chains (Left & Right)
Starter Motor Bolt
50Nm
Oil Pan to Block Bolt (M8)
23Nm
Oil Pan to Rear Seal Housing (M6)
10Nm
Thermostat Housing Bolt
10Nm
Transmission to Engine Bolt
50Nm
Torque Converter Bolt
60Nm 2995
Alloytec Timing Chain
Timing Chain
VZ – VE Commodore Alloytec 3.6 Litre The timing for this engine is carried out in two stages. It is important that you read all the instructions before commencing the job, especially the Notes and Cautions.
Warning! Retiming this engine requires the use of camshaft alignment tools EN 46105-1 and EN 46105-2. Do not attempt to carry this job unless you have these tools.
Timing Chain Removal 1. Disconnect battery earth lead. 2. Remove engine cover. 3. Remove air cleaner assembly and intake duct. 4. Disconnect crankcase ventilation and evap hoses. 5. Disconnect Inlet Manifold Runner Control and throttle plate wiring, remove upper intake manifold. 6. Remove the engine cover mounting bracket.
Note! DO NOT turn crankshaft or camshafts while timing chains are removed unless otherwise stated.
Note:
Disconnect battery before starting work.
8. Remove rocker covers.
Cover coil holes to ensure that no particles inadvertently fall into engine.
Remove spark plugs to ease turning the engine.
9. Drain cooling system. Remove upper and lower radiator hoses, coolant bleed and recovery hoses, cooling fans, and drive belt.
Turn engine in normal direction of rotation unless otherwise stated.
10. Remove harmonic balancer from crankshaft.
DO NOT turn engine by camshafts or other pulleys. Follow all tightening torques. Use Special Tools where directed.
2988
7. Remove ignition coils and spark plugs.
11. Unbolt power steering pump reservoir and relocate away from work area without disconnecting hoses. 12. Unbolt air-conditioning compressor and relocate away from work area without disconnecting refrigerant lines.
VACC Tech Talk – September 2009
Tech Talk
Alloytec Timing Chain
13. Remove camshaft position sensors and variable camshaft timing solenoids from engine. 14. Remove timing chain cover. 15. Turn crankshaft clockwise using special tool EN 46111, until the stage one (first) timing marks are aligned. See Diagrams #3 and #4. 16. Install alignment tool EN 46105-1 to the rear of LH camshaft. See Diagrams #1 & #2. You may need to use a spanner on the flat part of the camshafts to get the tool to fit.
Note:
Do not force or hammer the alignment tool onto the camshaft.
Diagram #3 Crankshaft at Stage One Timing Mark
17. Remove the RH timing chain tensioner, taking care not to loose any of the spring loaded components. 18. Remove the RH timing chain. 19. Remove the tensioner for the primary timing chain, taking care not to loose the spring-loaded components, and then remove the primary timing chain.
Diagram #1 EN 46105-1 Shown from rear fitted to LH Camshafts Note: Camshaft Flats are Parallel with Head Diagram #2 EN 46105-1 Shown from front fitted to LH Camshafts
20. Remove the tensioner for the LH timing chain, taking care not to loose spring-loaded components, and then remove the LH timing chain.
Caution:
If you are removing any sprockets, do not mix them up! The LH intermediate sprocket is marked with the letters LB, while the RH intermediate sprocket is marked RB. On both intermediate sprockets the word Front should be visible when installed.
Caution:
The primary camshaft drive chain lower guide is not separately serviceable. If the primary camshaft drive chain lower guide must be replaced, the oil pump must be replaced.
Note:
Check the timing chains to ensure that the chains have shiny or coloured links to enable retiming of the engine. If not you may need to mark the chains before removing. VACC Tech Talk – September 2009
Caution:
The oil pump is not serviceable. Once dissembled the pump must be replaced. Therefore, only disassemble the pump if you wish to confirm your prior diagnosis.
2989
Tech Talk
Alloytec Timing Chain LH Secondary Chain Intake Timing Marks
LH Secondary Chain Exhaust Timing Marks
L
R
IN
Diagram #4 Engine Timing Marks at Stage One Timing Position
EX
R
L
Primary Chain Timing Marks
LH Secondary Chain Intermediate Sprocket Timing Marks
Crankshaft Aligned with Stage One Timing Mark on Oil Pump
2990
Do not remove Primary Lower Chain Guide or dismantle Oil Pump. If required, these must be replaced as an assembly. VACC Tech Talk – September 2009
Tech Talk
Alloytec Timing Chain
Cleaning and Inspection •
Clean gaskets from timing chain cover and inspect for any damage.
•
Carefully clean the engine front cover sealing surfaces. Insert a piece of cardboard between the oil pan front and the oil pump in order to prevent any pieces of old gasket falling into the oil pan.
•
Check timing chain guides and sprockets for wear, gouges, or deformities.
•
Inspect the timing chains for wear and for cracked or loose rollers.
Note:
Diagram #5 Crankshaft at Stage One Timing Mark
Do Not Remove Lower Primary Chain Guide or Dismantle Oil Pump
Due to the tendency for these timing chains to stretch, it is recommended that, unless they have covered relatively few kilometres, they be replaced.
Timing Chain Installation
Note:
Note:
If reusing the chains ensure that they are refitted to their original position, and not swapped left and right. •
Clean and inspect the tensioners for debris, wear, and freedom of movement. Rotate plungers and lock into retracted positions.
•
Ensure that all seals and gaskets are replaced.
The valve timing on this engine is carried out in two stages. Stage 1, where the crankshaft timing mark is at approximately the 23-minute mark, is where the LH secondary chain and then the primary chain are fitted. Stage 2, where the crankshaft timing mark is at approximately the 43-minute mark, is where the RH secondary chain is fitted.
Stage One 1. Turn crankshaft so that the crankshaft timing mark is aligned with the first timing mark using special tool EN 46111. See Diagrams #3 and #4.
Note:
If the engine is still fitted to the vehicle it is best to use a mirror to check timing mark alignment. 2. Install alignment tool EN 46105-1 to the rear of LH camshaft. See Diagrams #1 and #2. Use a spanner on the flat part of the camshafts to get them into the correct position to enable the tool to fit.
Diagram #6 Triangular and Circular Timing Marks correspond with Right And Left VACC Tech Talk – September 2009
3. Turn LH intermediate chain sprocket to the position shown in Diagram #4.
2991
Tech Talk
Alloytec Timing Chain
5. Fit LH chain guides and tensioner.
EX
Stage Two
L
R
1. Turn the crankshaft clockwise until the crankshaft timing mark is aligned with the second timing mark using special tool EN 46111. See Diagrams #8 and #14.
IN
4. Install the LH chain to inner intermediate sprocket, ensuring that the bright plated or marked chain link can be seen through the timing mark hole in the sprocket. Fit the chain over the LH camshaft sprockets, aligning marked links with the circular timing marks (those marked with an ‘L’). R See Diagram #4.
L
Note:
After fitting tensioner, compress it with your hand to ensure that it unlocks the plunger, and applies tension to the chain.
Diagram #7 Primary Chain Tensioner
Diagram #8 Crankshaft at Stage Two Timing Mark 2. Fit the camshaft alignment tool EN 46105-2 to the rear of LH camshaft. Fit the camshaft alignment tool EN 46105-1 to the rear of RH camshaft. See Diagrams #10, #11 and #12. Use a spanner on the flat part of the camshafts to get them into the correct position to enable the tool to fit.
Tensioner plunger must be rotated and compressed till it is locked. Once fitted it must be compressed to release.
3. Install the RH chain to the sprockets, aligning the bright plated or marked chain links with the intermediate sprocket alignment hole and the camshaft sprocket triangular marking (those marked with an ‘R’). See Diagrams #9 and #14.
6. Install primary chain ensuring the stage one timing marks are aligned. The marked links need to align with the triangles on the intermediate sprockets and the dot on the crankshaft sprocket. See Diagrams #4 and #6. 7. Install the primary chain upper guide. 8. Refit the primary chain tensioner. Release the tensioner by pushing it in against spring pressure to unlock the plunger. 9. Remove the camshaft alignment tool EN 46105-1 from the rear of LH camshaft. 2992
Diagram #9 RH Intermediate Sprocket Chain Alignment Marks
VACC Tech Talk – September 2009
Tech Talk
Alloytec Timing Chain
4. Install chain guides and tensioner. This tensioner also needs to be released by pushing it in against spring pressure to unlock the plunger. 5. Recheck that the timing marks are all aligned. See Diagram #14.
Diagram #10 EN 46105-1 Shown from front fitted to RH Camshafts
6. Recheck the chain tensioners, to ensure they are released and are applying spring pressure to the chains. 7. Remove camshaft alignment tools EN 46105-1 and EN 46105-2 from the camshafts. 8. Rotate the crankshaft at least one full turn clockwise, using special tool EN 46111, to ensure that everything moves freely and smoothly. 9. Refit all parts in reverse order of disassembly, using new gaskets and seals.
Note: Diagram #11 EN 46105-1 Shown from rear fitted to RH Camshafts. Note: Camshaft Flats are Parallel with Head.
Two 8 x 1.25mm studs can be fitted to the block, to guide the timing chain cover when refitting. Fit the remaining bolts finger tight before removing the studs and refitting the original bolts. Then tighten cover bolts evenly.
Diagram #13 Special Tools
EN 46111
Diagram #12 EN 46105-2 Shown from rear fitted to LH Camshafts. Note: Camshaft Flats are at an angle. EN 461105 - 1 Special Tools Required are: •
EN 46111 - Crankshaft Turning Tool
•
EN 46105-1/2 - Camshaft Locking Tools
VACC Tech Talk – September 2009
EN 461105 - 2
2993
Tech Talk
Alloytec Timing Chain RH Secondary Chain Intake Timing Marks
RH Secondary Chain Exhaust Timing Marks L
R
L
IN
R
L
IN
R
EX
EX
R
L
RH Secondary Chain Intermediate Sprocket Timing Marks
Crankshaft Aligned with Stage Two Timing Mark on Oil Pump
Diagram #14 Engine Timing Marks at Stage Two Timing Position
2994
VACC Tech Talk – September 2009
Tech Talk 3.6 Alloytec Bolt Tension
Alloytec Timing Chain Notes
Torque
Camshaft Sprocket Bolt
58Nm
Camshaft Cap Bolt
10Nm
Camshaft Intermediate Sprocket Bolt
58Nm
Crankshaft Balancer Bolt
1st Step
100Nm
2nd Step
150 Degrees
Crankshaft Rear Oil Seal Housing
10Nm
Cylinder Head Bolt
M8 1st Step
15Nm
M8 2nd Step
60 Degrees
M11 1st Step
45Nm
M11 2nd Step
Loosen 120 Degrees
M11 3rd Step
30Nm
M11 4th Step
150 Degrees
1st Step
30Nm
2nd Step
75 Degrees
Flywheel Bolts
Heater Inlet/Outlet Pipes
10Nm
Intake Manifold Bolts
23Nm
Timing Chain Cover Bolt
1st Step
20Nm
2nd Step
60 Degrees
Bolt
25Nm
Cover Bolt
13Nm
Left Guide Bolt
13Nm
Tensioner Bolt
23Nm
Upper Guide Bolt
23Nm
Guide Bolt
23Nm
Shoe Bolt
23Nm
Tensioner Bolt
23Nm
Oil Pump
Primary Chain
Secondary Chains (Left & Right)
Starter Motor Bolt
50Nm
Oil Pan to Block Bolt (M8)
23Nm
Oil Pan to Rear Seal Housing (M6)
10Nm
Thermostat Housing Bolt
10Nm
Transmission to Engine Bolt
50Nm
Torque Converter Bolt
60Nm 2995
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