Camshaft sprocket tensioner - 1996 Toyota Camry

Did you take pictures while removing the originals? It's always a good habit. Below are the instructions you need to follow. Your own pics are very helpful when doing a big job like this.

1. Disconnect negative battery (1) cable.
2. Drain cooling system.
3. Remove upper intake manifold.
4. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.

CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

1. Align crankshaft sprocket timing mark to mark on oil pump housing (2). The mark on oil pump housing is 600 ATDC of #1 cylinder.

CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

1. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head.

1. Disconnect and remove camshaft position sensor (4) from left cylinder head.
2. Remove timing chain guide access plugs (3) from cylinder heads.

NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.

1. Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper (1) (if equipped) and sprocket.
2. Remove left side camshaft sprocket attaching bolts and remove sprocket.
3. Remove lower chain guide (7) and tensioner arm (8).
4. Remove the primary timing chain (5).
5. Remove crankshaft sprocket (6).

INSTALLATION

1. Inspect all sprockets (4,9,11) and chain guides (2,5,10). Replace if worn.
2. For crankshaft sprocket installation procedures Refer to CRANKSHAFT SPROCKET.
3. If removed, install right and left side short chain guides (11). Tighten attaching bolts to 28 Nm (250 inch lbs.) .
4. Align crankshaft sprocket timing mark to the mark on oil pump housing (3).

NOTE: Lubricate timing chain and guides with engine oil before installation.

1. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (1).

1. Lower the primary chain with left side sprocket through the left cylinder head opening.

NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.

1. Loosely position left side camshaft sprocket over camshaft hub.
2. Align timing (plated) link to the crankshaft sprocket timing mark (3).
3. Position primary chain onto water pump drive sprocket (10).
4. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely position over camshaft hub.
5. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
6. Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 28 Nm (250 inch lbs.) .

NOTE: Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

1. Install chain guide access plugs to cylinder heads. Tighten plugs to 20 Nm (15 ft. lbs.) .

NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

1. Purge oil from timing chain tensioner using the following procedure:

1. Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
2. Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

1. Reset timing chain tensioner using the following procedure:

1. Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
2. Apply a downward force until tensioner is reset.

NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball.

CAUTION: Ensure the tensioner is properly reset. The tensioner body (4) must bottom against the top edge of Special Tool 8186 (3). Failure to properly perform the resetting procedure may cause tensioner jamming.

NOTE: Inspect the tensioner O-ring (2) for nicks or cuts and make sure the snap ring (1) is correctly installed, replace as necessary.

1. Install the reset chain tensioner (1) into the right cylinder head.
2. Position tensioner retaining plate (2) and tighten bolts (1) to 12 Nm (105 inch lbs.) .

1. Starting at the right cylinder bank, first position the camshaft damper (1) (if equipped) on camshaft hub, then insert a 3/8 square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 inch lbs.) .
2. Turn the left side camshaft by inserting a 3/8 square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 inch lbs.).
3. Rotate engine slightly clockwise to remove timing chain slack, if necessary.

1. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then release the tensioner arm. Verify the tensioner is activated (extends).

1. Install camshaft position sensor (2) and connect electrical connector.
2. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
3. Install upper intake manifold.

NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds.

1. Fill cooling system.

Procedure is pasted below. Please let me know if you have questions.
Removal & Installation2.2L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove or disconnect the following:
   NOTE The timing chain has 2 matching colored links and 1 uniquely colored link.
   Negative battery cable, PCV hose, Fuel line bracket, Ignition coil and module assembly Ground strap from camshaft cover, Camshaft cover, Front fender liner, Accessory drive belt Crankshaft balancer pulley, Accessory drive belt tensioner, Front cover-to-water pump bolt Remaining front cover bolts, Front cover
   
5. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link (2) at the 5 o-clock position.
6. Confirm that the INT diamond on the intake camshaft sprocket is aligned with the uniquely colored link at (1) the 2 o-clock position.
7. Confirm that the EXH triangle on the exhaust camshaft sprocket is aligned with the matching colored link (3).
8. Remove or disconnect the following:
   NOTE Use a 24 mm wrench to hold the camshafts to prevent them from turning.
   Timing chain tensioner, Fixed timing chain guide access plug, Fixed timing chain guide Upper timing chain guide, Exhaust camshaft sprocket, Timing chain tensioner guide Intake camshaft sprocket, Timing chain through the top of the cylinder head Crankshaft sprocket
   
   
   

   Fig. Lining up the crankshaft sprocket mark with the colored link in the 5 o-clock position (2).
   
   
   
   

   Fig. Aligning the intake camshaft sprocket mark with the colored link in the 2 o-clock position (1).
   
   
   
   

   Fig. Aligning the exhaust camshaft sprocket (3).
   

To install:

1. Install the crankshaft sprocket with the timing mark in the 5 o-clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head.
4. Route the timing chain around the crankshaft sprocket and line up the first marching colored link (2) with the timing mark on the crankshaft sprocket.
5. Install the exhaust camshaft sprocket with a new bolt loosely onto the exhaust camshaft.
6. Align the timing mark on the sprocket with the last matching colored (3).
7. If necessary, align the camshaft as follows:
   1. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft.
   2. Turn the crankshaft 45 degrees in either direction.
   3. Turn the intake camshaft to the appropriate location.
   4. Turn the crankshaft back to top dead center (TDC).
8. When the sprocket seats in on the camshaft, tighten the sprocket bolt hand tight.
9. Verify all of the colored links and the appropriate timing marks are still aligned.
10. Install the fixed timing chain guide. Tighten the bolts to 133 inch lbs. (15 Nm).
11. Install the upper timing chain guide. Tighten the bolts to 89 inch lbs. (10 Nm).
12. Using a 24 mm wrench to hold the camshafts, tighten the camshaft sprocket bolts 63 ft. lbs. (85 Nm) plus 30 degrees.
13. Measure the timing chain tensioner from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inches (72 mm) front end to end. A tensioner in the active state will measure 3.35 inches (85 mm) from end to end.
14. If the timing chain tensioner is not in the compressed state, perform the following steps:
    1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
    2. Install the bottom half of the Tensioner tool J-45027-2 into a vise.
    3. Install the notch end of the piston assembly into the bottom half of the tensioner tool.
    4. Using the top half of the Tensioner tool J-45027-1, turn the ratchet cylinder into the piston.
    5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore.
    
    
15. Install the timing chain tensioner assembly. Tighten to 66 ft. lbs. (75 Nm).
16. Release the timing chain tensioner by compressing it approximately 0.08 inches (2mm). Feed a rubber-tipped tool down through the cam drive chest to reset on the cam chain. Give the tool a sharp jolt diagonally downwards to release the tensioner.
17. Install the timing chain oiling nozzle.
18. Install the timing chain guide bolt access hold plug with silicone sealant on the threads. Tighten the plug to 59 ft. lbs. (90 Nm).
19. Install or connect the following:
    
    Camshaft cover. Tighten the bolts to 89 inch lbs. (10 Nm). Front cover with new gasket. Tighten the bolts to 18 ft. lbs. (25 Nm). Accessory drive belt tensioner. Tighten the bolts to 33 ft. lbs. (45 Nm). Crankshaft balancer pulley using a new bolt. Tighten the bolt to 74 ft. lbs. (100 Nm) plus 75 degrees. Accessory drive belt, Front fender liner, Ground strap to camshaft cover Ignition coil and module assembly, Fuel line bracket, Air intake assembly, Negative battery cable
20. Refill the cooling system to the correct level.
21. Refill the engine with oil to the correct level.
22. Start the engine and check for leaks.
    
    
    

    Fig. Compressing the timing chain tensioner-2.2L engine.
    

Is this what you needed?

Fig. Fig. 14: Sprocket timing for belt installation-3.0L engines

Fig. Fig. 15: Secure the sprocket when removing or installing the nut-3.0L engines

Fig. Fig. 16: Timing belt tensioner-3.0L engines

Fig. Fig. 17: Positioning the tensioner-3.0L engines
The timing belt can be inspected by removing the upper (front outer) timing cover.

1. Disconnect the negative battery cable.
2. Remove the accessory drive belts.
3. Remove the timing belt covers.
4. Identify the timing belt running direction to avoid reversal during installation.
5. Loosen timing belt tensioner bolt and remove timing belt.
6. Remove the crankshaft sprocket flange.

To install:

1. Rotate the crankshaft sprocket until timing mark on crankshaft sprocket is lined up with the oil pump timing mark at 1 o'clock position.
2. Rotate the (inner) camshaft sprocket until mark on (inner) camshaft sprocket is lined up with the timing mark on alternator bracket.
3. Rotate the (outer) camshaft sprocket (radiator side) until mark on the sprocket is lined up with the timing mark on the timing belt inner cover. Refer to timing belt illustration.
4. Install the timing belt on the crankshaft sprocket while maintaining pressure on the tensioner side.
5. Position the timing belt over the camshaft sprocket (radiator side). Next, position the belt under the water pump pulley, then over the (inner) sprocket and finally over the tensioner.
6. Apply rotating force in the opposite direction to the camshaft sprocket (radiator side) to create tension on the timing belt tension side.
7. Rotate the crankshaft in a clockwise direction and recheck engine timing marks.
8. Install the crankshaft sprocket flange.
9. Loosen the tensioner bolt and allow tensioner spring to tension the belt.
10. Again rotate the crankshaft in a clockwise direction (2) full turns. Recheck the engine timing. Tighten the tensioner bolt to 23 ft. lbs. (31 Nm).
11. Install the timing covers.
12. Install the accessory drive belts.
13. Connect battery negative cable.

Hi, this engine uses plated links in the chain to match marks on the gears. See figure and installation procedure below. Let me know if you have any questions and thanks for using FixYa.

1. Install the timing chain by performing the following procedure:

1. Verify that the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing.
2. Place the left side primary timing chain sprocket onto the chain, while aligning the timing mark on the sprocket to the 2 plated links on the chain.
3. Lower the chain with the left sprocket through the left cylinder head opening.
4. Loosely position the left camshaft sprocket over the camshaft hub.
5. Align the plated link to the crankshaft sprocket timing mark.
6. Position the timing chain around the water pump drive sprocket.
7. Align the right camshaft sprocket timing mark to the plated link on the timing chain and loosely position the sprocket over the camshaft hub.
8. Verify that all the plated links are aligned to their proper timing marks.
   

1. Install the left lower timing chain guide and tensioner. Torque the bolts to 21 ft. lbs. (28 Nm).
   NOTE Inspect the timing chain guide access plug O-rings before installing. Replace damaged O-rings as necessary.
   
2. Install the timing chain guide access plug to the left cylinder head and torque to 15 ft. lbs. (20 Nm).
   NOTE To reset the timing chain tensioner, oil will first need to be purged from the tensioner.

1. Purge oil from the timing chain tensioner using the following procedure:

1. Remove the tensioner from the tensioner housing.
2. Place the check ball end of the tensioner into the shallow end of the Tensioner Resetting Special tool 8186.
3. Using hand pressure, slowly depress the tensioner until oil is purged from the cylinder.
4. Reinstall the tensioner into the tensioner housing.

1. Reset the timing chain tensioner using the following procedure:

1. Position the cylinder plunger into the deeper side of the Tensioner Resetting special tool 8186. Apply a downward force until the tensioner is reset.
   

WARNING

Ensure that the tensioner is properly reset. The tensioner body must be bottomed against the top edge of the Tensioner Resetting Special tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.

1. Install the chain tensioner into the right cylinder head.
   
2. At the right cylinder head, insert a 3 / 8 in. square drive extension with a breaker bar into the intake camshaft drive hub. Rotate the camshaft until the camshaft hub aligns with the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and torque to 21 ft. lbs. (28 Nm).
3. Turn the left camshaft by inserting a 3 / 8 in. square drive extension with a breaker bar into the intake camshaft drive hub. Rotate the camshaft until the camshaft hub aligns with the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and torque to 21 ft. lbs. (28 Nm).
4. If necessary, rotate the engine slightly clockwise to remove any slack in the timing chain.
5. To arm the timing chain tensioner: Use a flat-bladed prytool to gently pry the tensioner arm towards the tensioner slightly. Then, release the tensioner arm. Verify the tensioner extends.
6. Inspect and replace the timing chain cover gasket and oil seal.
7. Apply a 1 / 8 in. (3mm) bead of sealer at the parting line of the oil pan and engine block.
   NOTE When installing the timing cover, guide the seal over the crankshaft to prevent damage to the seal-s lip.
   

Install or connect the following:

Timing cover and gasket and torque the M10 bolts to 40 ft. lbs. (54 Nm) and the M6 bolts to 105 inch lbs. (12 Nm)

Accessory drive belt tensioner pulley

Power steering pump

Crankshaft damper

Crankshaft center bolt and torque the bolt to 125 ft. lbs. (170 Nm) using tool 8191

Accessory drive belts

Fan module and electrical wiring harness

Upper radiator crossmember

Negative battery cable

Timing Chain and Gears REMOVAL & INSTALLATION 2.2L Engine Fig. 1: The timing marks on the sprockets should be in alignment. If not, turn the crankshaft until the marks are aligned
Fig. 2: The timing chain tensioner is retained by a Torx head bolt (1) and a regular hex head bolt (2)
Fig. 3: Unfasten the camshaft sprocket bolt
Fig. 4: Remove the camshaft sprocket and the timing chain at the same time . . .
Fig. 5: . . . then remove the tensioner assembly
Fig. 6: Compress the tensioner spring and insert a cotter pin or nail in the hole provided to hold the tensioner in position

1. Disconnect the negative battery cable.
2. Remove the front cover as previously detailed.
3. Place the No. 1 piston at TDC of the compression stroke so that the marks on the camshaft and crankshaft sprockets are in alignment (see illustration).
4. Loosen the timing chain tensioner nut as far as possible without actually removing it.
5. Remove the camshaft sprocket bolts and remove the sprocket and chain together. If the sprocket does not slide from the camshaft easily, a light blow with a soft mallet at the lower edge of the sprocket will dislodge it.
6. Using a suitable gear puller, remove the crankshaft sprocket. To install:
   
7. Press the crankshaft sprocket back onto the crankshaft.
8. Install the timing chain over the camshaft sprocket and then around the crankshaft sprocket. Make sure that the marks on the two sprockets are in alignment (see illustration). Lubricate the thrust surface with Molykote® or its equivalent.
9. Align the dowel in the camshaft with the dowel hole in the sprocket and then install the sprocket onto the camshaft. Use the mounting bolts to draw the sprocket onto the camshaft and then tighten to 66-68 ft. lbs. (91-95 Nm).
10. Lubricate the timing chain with clean engine oil. Tighten the chain tensioner.
11. Installation of the remaining components is in the reverse order of removal. Fig. 7: Exploded view of the timing chain and sprockets - 2.2L OHV engine
    

Timing Belt Removal & Installation 3.0L Engine To Remove:
Exploded view of the timing belt and sprocket assembly (3.0L engine)

1. Disconnect the negative battery cable.
2. Remove the accessory drive belts. Remove the engine mount insulator from the engine support bracket.
3. Remove the engine support bracket. Remove the crankshaft pulleys and torsional damper. Remove the timing belt covers.
4. Rotate the crankshaft until the sprocket timing marks are aligned. The crankshaft sprocket timing mark should align with the oil pump timing mark. The rear camshaft sprocket timing mark should align with the generator bracket timing mark and the front camshaft sprocket timing mark should align with the inner timing belt cover timing mark.
5. If the belt is to be reused, mark the direction of rotation on the belt for installation reference. Mark the direction of travel for the timing belt for correct installation
   
6. Loosen the timing belt tensioner bolt and remove the timing belt.
7. If necessary, remove the timing belt tensioner. Turn the center tensioner pulley bolt until the timing belt has enough slack . . .
   . . . then slide the timing belt off of the camshaft sprockets
   
8. Remove the crankshaft sprocket flange shield and crankshaft sprocket.
9. Hold the camshaft sprocket using spanner tool MB990775 or equivalent, and remove the camshaft sprocket bolt and washer. Remove the camshaft sprocket.

To Install:

1. Install the camshaft sprocket on the camshaft with the retaining bolt and washer. Hold the camshaft sprocket using spanner tool MB990775 or equivalent, and tighten the bolt to 70 ft. lbs. (95 Nm).
2. Install the crankshaft sprocket.
3. If removed, install the timing belt tensioner and tensioner spring. Hook the spring upper end to the water pump pin and the lower end to the tensioner bracket with the hook out.
4. Turn the timing belt tensioner counterclockwise full travel in the adjustment slot and tighten the bolt to temporarily hold it in this position.
5. Rotate the crankshaft sprocket until its timing mark is aligned with the oil pump timing mark.
6. Rotate the rear camshaft sprocket until its timing mark is aligned with the timing mark on the generator bracket.
7. Rotate the front (radiator side) camshaft sprocket until its mark is aligned with the timing mark on the inner timing belt cover.
8. Install the timing belt on the crankshaft sprocket while keeping the belt tight on the tension side. NOTE: If the original belt is being reused, be sure to install it in the same rotational direction.
   
9. Position the timing belt over the front camshaft sprocket (radiator side). Next, position the belt under the water pump pulley, then over the rear camshaft sprocket and finally over the tensioner. CAUTION
   If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine, because the pistons may be hitting the valves.
   Rent or borrow the special tool to hold the camshaft sprockets steady . . .
   . . . while loosening the center retaining bolt on the camshaft pulley, then . . .
   . . . remove the camshaft sprocket from the end of the camshaft
   Timing belt tensioner and spring positions
   Timing belt routing and timing mark locations
   
   
10. Apply rotating force in the opposite direction to the front camshaft sprocket (radiator side) to create tension on the timing belt tension side. Check that all timing marks are aligned.
11. Install the crankshaft sprocket flange.
12. Loosen the tensioner bolt and allow the tensioner spring to tension the belt.
13. Rotate the crankshaft two full turns in a clockwise direction. Turn the crankshaft smoothly and in a clockwise direction only.
14. Again line up the timing marks. If all marks are aligned, tighten the tensioner bolt to 250 in. lbs. (28 Nm). Otherwise repeat the installation procedure.
15. Install the timing belt covers. Install the engine support bracket. Tighten the support bracket mounting bolts to 35 ft. lbs. (47 Nm).
16. Install the engine mount insulator, torsional damper and crankshaft pulleys. Tighten the crankshaft pulley bolt to 112 ft. lbs. (151 Nm).
17. Install the accessory drive belts.
18. Reconnect the negative battery cable.
19. Run the engine and check for proper operation.

Timing Belt and Sprockets REMOVAL & INSTALLATION Fig. 1: If you plan on reusing the timing belt, make sure you note the direction of the rotation before removal Fig. 2: If the special tool is unavailable, a suitable length and width straight edge can be used to align the camshafts Fig. 3: Camshaft alignment using the special service tool Fig. 4: Insert the crankshaft damper bolt to turn the crankshaft and . . . Fig. 5: . . . align the camshafts and the . . . Fig. 6: . . . crankshaft before removing the old belt Fig. 7: Loosen the timing belt tensioner pulley bolt, slide the tensioner back and . . . Fig. 8: . . . tighten the bolt to the farthest right hand side as possible to hold the release the tensioner pulley so that the belt can be removed Fig. 9: . . . remove the belt starting from around the camshaft pulleys Fig. 10: Installation of the tensioner spring and retaining bolt For information on timing belt recommended replacement interval, refer to Section 1. CAUTION
The 2.0L engine is an interference motor. Extending the replacement interval could lead to the belt breaking and severe and costly engine damage. Care must be taken if rotating the crankshaft or camshafts with the belt off, if resistance is felt, do not force them to turn.

1. Disconnect the negative battery cable.
2. Remove the timing belt covers as outlined in this Section.
3. Remove the valve cover.
4. Place Camshaft Alignment Timing Tool T94P-6256-CH or equivalent, into the slots of both camshafts at the rear of the cylinder head to lock the camshafts into position. NOTE: If the special tool is unavailable, a suitable length and width straight edge can be used to align the camshafts.
   
5. Loosen the camshaft timing belt tensioner pulley retaining bolt and move the tensioner pulley to relieve the tension on the timing belt.
6. Temporarily tighten the tensioner in this position. NOTE: If the timing belt is to be reused, mark the belt for the direction of rotation before removing to prevent premature wear or failure.
   
7. Remove the timing belt.
8. If required, remove the sprockets as follows:
   1. Hold the camshaft with an appropriate camshaft sprocket holding tool.
   2. Loosen and remove the camshaft sprocket retaining bolt.
   3. Remove the sprocket from the camshaft.
   4. Repeat the procedure for the 2nd camshaft sprocket.
   5. Remove the crankshaft sprocket.
9. Slide the crankshaft sprocket onto the crankshaft aligning the key-way.
10. Align the camshafts using the Camshaft Alignment Timing Tool T94P-6256-CH. NOTE: If the special tool is unavailable, a suitable length and width straight edge can be used to align the camshafts.
    
11. Reinstall the sprockets onto the camshafts and loosely install the camshaft retaining bolts.
12. Tighten the camshaft sprocket retaining bolts to 47–53 ft. lbs. (64–72 Nm) .
13. Loosely install the crankshaft pulley to verify that the engine is at TDC. Realign the marks if they have moved.
14. Verify that the camshafts are aligned. NOTE: It is recommended to purchase a tensioner spring and retaining bolt through the dealer parts to apply the proper tension for used or new belt installations. The spring is bolted to the tensioner assembly and becomes a part of the engine. Ignore this notice if the tensioner spring is already installed.
    
15. Reinstall the retaining bolt (W700001-S309) into the hole provided in the cylinder block and place the tensioner spring (6L277) between the bolt and the camshaft timing belt tensioner pulley.
16. Tighten the retainer bolt to 71–97 inch lbs. (8–11 Nm) .
17. Remove the crankshaft pulley and install the timing belt onto the crankshaft sprocket, then onto the camshaft sprockets working in a counterclockwise direction.
18. Tighten the camshaft sprocket retaining bolts to 47–53 ft. lbs. (64–72 Nm) .
19. Be sure that the span of the camshaft timing belt between the crankshaft sprocket and the exhaust camshaft sprocket is not loose.
20. Be sure that the camshaft timing belt is securely aligned on all sprockets.
21. Reinstall the lower timing belt cover and tighten the retaining bolts to 53–71 inch lbs. (6–8 Nm) .
22. Apply silicone sealer to the key-way of the crankshaft pulley and install. Tighten the retaining bolt to 81–89 ft. lbs. (110–120 Nm) .
23. Inspect the timing mark on the crankshaft pulley to verify that the engine is still at TDC.
24. Loosen the camshaft timing belt tensioner pulley retaining bolt and allow the tensioner spring attached to the pulley to draw the tensioner pulley against the camshaft timing belt.
25. Remove the camshaft alignment timing tool from the camshafts at the rear of the engine.
26. Turn the crankshaft two revolutions in a clockwise direction.
27. Tighten the camshaft timing belt tensioner pulley retaining bolt to 26–30 ft. lbs. (35–40 Nm) .
28. Recheck that the crankshaft timing mark is at TDC for the No. 1 piston, and that both camshafts are in alignment using the camshaft alignment timing tool. NOTE: A slight adjustment of the camshafts to allow the insertion of the camshaft alignment timing tool is permissible as long as the crankshaft stays at the TDC location.
    
29. An appropriate camshaft sprocket holding tool can be used to move the camshaft sprocket (s) if a slight adjustment is required.
30. If a camshaft is not properly aligned, perform the following procedure:
    1. Loosen the retaining bolt securing the sprocket to the camshaft while holding the camshaft sprocket from turning with the sprocket holding tool.
    2. Turn the camshaft until the camshaft alignment timing tool can be installed.
    3. Verify that the crankshaft timing mark is at TDC for the No. 1 cylinder.
    4. While holding the camshaft sprocket with the camshaft sprocket holding tool, tighten the retaining bolt to 47–53 ft. lbs. (64–72 Nm) .
    5. Remove the tool and rotate the crankshaft two revolutions (clockwise) .
    6. Verify that the camshafts are aligned and that the crankshaft is at TDC for the No. 1 cylinder.
31. Install the valve cover.
32. Install the timing belt covers.
33. Connect the negative battery cable.

Dear Friend
Removal: Support engine: remove -engine mounting, auxiliary drive belt, water pump pulley, crankshaft pully bots & crankshaft pully, timing belt covers....turn crankshaft to TDC on No 1 cylinder, ensure crankshaft sprocket, camshaft sprocket, oil pump sprocket & balancer shaft sprocket timing marks lighned. Pls note: Timing marks on camshaft sprockets should align with cylinder head uppter face, dowl pins on camshaft sprockets should face downwards....Slacken tensioner botl. Move tensioner away from belt & tighten bolt.
Remove: automatic tensioner unit bolts, automatic tensioner unit, timing belt, crankshaft bolt, crankshaft sprocket, crankshaft sprocket guide washer...slacken balancer shaft belt rensioner bolt, move tensioner away from belt & lightly tighten bolt...Remove balancer shaft belt.

Installation:
ensure timeing marks aligned.Note: Timing marks on camshaft sprockets ahould align with cylinder head upper face, exhaust sprocket mark is on recess but inlet sprocket mark is on tooth. To check oil pump sprocket positionded sorrectly: remove blanking plug from cylinder block, insert 8mm diameter Phillips screwdriver in hole. ensure screwdriver is inserded 60mm from face of cylinder block. If screwdriveer can only be inserted 20mm-turn oil pump sprocket 360". Inset screwdiver again.
Fit balancer shaft delt in anti-clockwise direction starting at crandkshaft sprocket....Slacken balancer shaft belt tensioner notl, turn tensioner clockwise to tension belt. Tighten bolt to 15-22 Nm... Applu thump pressure to belt at tentioner, belt should deflect 5-7mm. If not: Repeat tensioning procedure.... Install - chankshaft sprocket guide washer & crankshaft sprocket.
Thighten crankshaft centre bolt, tightening torque:110-130Nm. Please note, ensure crankshaft sprocket guide washer is fittet correctly. oil threads & contact face crankshaft botl before fitting.

I'm not sure what you may be "doing wrong", but here is the manufacturer procedure for aligning the timing marks.


^Refer to this diagram during step 12.

^Refer to this diagram during step 13.

^Refer to this diagram for step 19.

1. Align crankshaft sprocket timing mark to the mark on oil pump housing. NOTE: Lubricate timing chain and guides with engine oil before installation.
2. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links.
3. Lower the primary chain with left side sprocket through the left cylinder head opening. NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.
4. Loosely position left side camshaft sprocket over camshaft hub.
5. Align timing (plated) link to the crankshaft sprocket timing mark.
6. Position primary chain onto water pump drive sprocket.
7. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain and loosely position over camshaft hub.
8. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
9. Install left side lower chain guide and tensioner arm. Tighten attaching bolts to 28 Nm (250 in. lbs.). NOTE: Inspect oil ring on chain guide access plug before installing. Replace O-ring as necessary.
10. Install chain guide access plug to left side cylinder head. Tighten plug to 20 Nm (15 ft. lbs.)
11. NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.
12. Purge oil from timing chain tensioner using the following procedure:
a) Place the check ball end of tensioner into the shallow end of Special Tool 8186.
b) Using hand pressure, slowly depress tensioner until oil is purged from tensioner.
13. Reset timing chain tensioner using the following procedure:
a) Position cylinder plunger into the deeper end of Special Tool 8186.
b) Apply a downward force until tensioner is reset. NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball. CAUTION: Ensure the tensioner is properly reset. The tensioner body must bottom against the top edge of Special Tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.
14. Install the reset chain tensioner into the right cylinder head.
15. Position tensioner retaining plate and tighten bolts to 12 Nm (105 in. lbs.).
16. Starting at the right cylinder bank, insert a 3/8" square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 in. lbs.).
17. Turn the left side camshaft by inserting a 3/8" square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 in. lbs.).
18. Rotate engine slightly clockwise to remove timing chain slack, if necessary.
19. To arm the timing chain tensioner: Use a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then, release the tensioner arm. Verify the tensioner is armed (extends).
20. Install the timing chain cover, crankshaft damper, and cylinder head covers.
21. Install camshaft position sensor and connect electrical connector.

Hope this helps!
Mitchell

Here is All Lititure But Pictures Wont show up on FixYa for some reason, I can Email it ALL to you Just Send Me A Request to my Nickname here @aol.com


SPECIAL TOOLS REQUIRED (or equivalents)

• J-36008, Camshaft sprocket timing alignment pins.
• J-39579, Camshaft sprocket wrench.

CAUTIONS:

• The timing chain on the 1996 LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam Engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used.
• The timing chain and crankshaft sprocket MUST be marked so that they are reinstalled with the same side facing out at the time of reassembly.
• Failure to follow the removal and installation procedures could result in severe engine damage.

REMOVE OR DISCONNECT

1. Negative battery cable.
2. Front cover, refer to Timing Cover / Service and Repair .
3. Rotate crankshaft in clockwise direction until camshaft and crankshaft timing marks are aligned.
4. Timing chain guides.
5. Raise and support vehicle.
6. Ensure slack in timing chain is above tensioner assembly, then remove chain tensioner. The timing chain must be disengaged from grooves in tensioner shoe to permit removal of shoe. Position a suitable screwdriver under timing chain while pulling shoe outward. If difficulty is encountered in removing tensioner shoe, proceed as follows:

1. Lower vehicle, then while holding the intake camshaft sprocket with J-39579, remove sprocket bolt and washer.
2. Remove washer, then install bolt into camshaft by hand.
3. Position a suitable three jaw puller into intake camshaft sprocket relief holes and remove sprocket. CAUTION: Do NOT pry on camshaft sprocket as damage to sprocket or timing chain housing may result.

1. Tensioner assembly attaching bolts and tensioner assembly.
2. MARK CRANKSHAFT SPROCKET AND TIMING CHAIN outer surface for reassembly.
3. Timing chain.

INSTALL OR CONNECT

1. Intake camshaft sprocket onto camshaft with surface marked during removal showing.
2. Intake camshaft sprocket retaining bolt and washer, torque to 70 Nm (52 ft lbs) while holding the sprocket with J-39579 (if removed).
3. Timing pins, J-36008, through holes in camshaft sprockets into holes in timing chain housing to position camshafts for proper timing. If camshafts are out of position and must be rotated more that 1/8 turn to insert timing pins:

1. Crankshaft MUST be rotated 90°clockwise off of TDC in order to give the valves adequate clearance to open.
2. Once the camshafts are in position and the timing pins have been installed rotate crankshaft COUNTERCLOCKWISE to TDC. CAUTION: Do NOT rotate the crankshaft clockwise to TDC, valve or piston damage could occur.

1. Timing chain over exhaust camshaft sprocket, around idler sprocket and around crankshaft sprocket.
2. Set camshaft sprockets at timed position and install timing chain. Remove timing pin from intake camshaft. Using J-39579, rotate the intake camshaft sprocket counterclockwise until timing chain can be installed over sprocket. Release J-39579 after timing chain has been installed over sprocket. The length of chain between intake and exhaust camshaft sprockets should tighten. The timing pin should easily fit through intake camshaft sprocket timing hole into timing chain housing timing hole. If timing pin does not fully index, the camshafts are NOT timed correctly and the procedure MUST be repeated.
3. With timing pins installed, raise and support vehicle.
4. With slack removed from timing chain between intake camshaft sprocket and crankshaft sprocket, timing marks on crankshaft and engine block should be aligned. If the marks are not aligned, move timing chain one tooth forward or rearward to align marks. Remove slack and recheck marks.
5. Reload tensioner assembly to zero position as follows:

1. Form a keeper out of heavy gauge wire into a U-shaped piece with a half inch opening.
2. Apply slight force on tensioner blade to compress plunger.
3. Insert small screwdriver into reset access hole and pry rachet pawl away from ratchet teeth while forcing the plunger completely in the hole.
4. Install keeper between access hole and blade.

1. Tensioner assembly to chain housing and recheck plunger assembly installation, noting long end is toward crankshaft.
2. Tighten timing chain tensioner bolts to 10 Nm (89 in lbs) .
3. Lower vehicle to point where timing pins can be removed from camshaft sprockets.
4. Rotate crankshaft two revolutions in the clockwise direction. Align crankshaft keyway with the mark on cylinder block and reinstall timing pins through camshaft sprockets into housing timing holes. Timing pins should slide easily through timing holes. If timing pins cannot be inserted easily, repeat procedure to properly time engine. CAUTION: If the engine is not correctly timed, severe engine damage could occur.
5. Timing chain guides.
6. Engine front cover.
7. Negative battery cable.