How to set timing chain marks for double overhead camshaft 2.4 engine

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

Table of Contents Removal Installation Print Options Print Text Only Print Text and images Print Camshaft, Replace Removal 1. Bring lock carrier into service position as follows: a. Remove radiator grille. b. Remove upper bolts (2), Fig. 1. c. Remove quick release screw (6) from below, Fig. 1. d. Remove bolts (5 and 4) pointing upward in area of wheel housing liner, Fig. 1. e. With aid from an assistant, pull cover parallel out of guides. f. Disconnect harness connectors of installed electrical components and hoses. g. Remove noise insulation. h. Remove intake air duct between lock carrier (1) and air cleaner housing at lock carrier, Fig. 2. i. Remove bolt (5) on bumper carrier (4) and install guide rods tool No. 3411, or equivalent, (6) on righthand and lefthand longitudinal member, Fig. 2. j. Remove bolts (2 and 3), Fig. 2. k. Lock carrier (1) can be pulled approximately .39 inch toward front onto guide rods tool No. 3411, (2), Fig. 3. 2. Remove upper toothed belt guard. 3. Bring camshaft gear to marking for TDC cylinder 1 by turning crankshaft. Marking on camshaft gear must be flush with marking on cylinder head cover, Fig. 4. 4. Loosen tensioner and remove toothed belt from camshaft sprocket. 5. Turn crankshaft back slightly. 6. Remove camshaft sprocket. To loosen bolt, counter hold camshaft gear using tool No. 3036, or equivalent. 7. Remove hall sensor housing. 8. Remove washer and cover for hall sensor. 9. Clean drive chain and camshaft chain sprockets across from both arrows on bearing caps and mark installed position with a color marking. Do not mark chain using a center punch or similar means. Distance between both arrows or colored markings consists of 16 rollers of drive chain, Fig. 5. 10. Secure camshaft adjuster or chain tensioner using bracket for chain adjustment tool No. 3366, or equivalent. If chain tensioner retainer is fastened too tightly, chain tensioner or camshaft adjuster can be damaged, Fig. 6. 11. First remove bearing caps 3 and 5 from intake and exhaust camshafts, Fig. 7. 12. Remove double bearing cap. 13. Remove both bearing caps from chain gears on intake and exhaust camshafts. 14. Remove securing bolts of camshaft adjuster/chain tensioner. 15. Alternating in diagonal sequence, loosen bearing caps 2 and 4 of intake and exhaust camshafts and remove. 16. Remove intake and exhaust camshaft, chain tensioner or camshaft adjuster and chain tensioner retainer tool No. 3366, or equivalent. Installation When installing the camshafts, cam lobes for cylinder 1 must point upward. When installing bearing caps, verify marking on cap is readable from intake side of cylinder head. 1. When reusing old drive chain, mount drive chain according to color markings onto both camshafts. When using a new drive chain, distance between notches (A) and (B) must be 16 rollers on chain, Fig. 8. Illustration shows where first and sixteenth drive chain rollers must be installed on chain gears. 2. Notch (A) is slightly offset inward toward chain roller (1), Fig. 8. 3. Replace rubber/metal seal for camshaft adjuster or chain tensioner and coat hatched surface with thin coat of sealant D 454 300 A2, or equivalent, Fig. 9. 4. Insert camshaft adjuster/chain tensioner between drive chain. 5. Oil running surfaces of both camshafts. 6. Insert camshafts with drive chain and camshaft adjuster/chain tensioner into cylinder head. 7. Tighten camshaft adjuster/chain tensioner to specification, pay attention to bushing. 8. Alternating in diagonal sequence, tighten bearing caps 2 and 4 of intake and exhaust camshafts and tighten to specification, pay attention to bushing, Fig. 7. 9. Install both bearing caps on gears on intake and exhaust camshafts. Inspect camshaft for proper adjustment (arrows) and tighten bearing cap to specification, pay attention to alignment bushing, Fig. 10. 10. Remove chain tensioner/camshaft adjuster tool No. 3366, or equivalent. 11. Coat hatched surfaces of double bearing cap lightly using sealant D 454 300 A2, or equivalent, install and tighten to specification, pay attention to bushing, Fig. 11. 12. Install remaining bearing caps and tighten to specification, pay attention to alignment bushing. 13. Install camshaft gear, thin rib toward outside (arrows) and TDC marking visible and tighten screw to specification, use retainer tool No. 3036, or equivalent, Fig. 12. 14. Inspect setting of camshafts to each other. 15. After installing camshafts, engine may not be started for approximately 30 minutes. Hydraulic adjusting elements must seat themselves, otherwise valves will seat themselves on pistons. 16. Pistons must not be positioned at TDC. Ensure that crankshaft is still positioned before cylinder 1 TDC. 17. Align marking on camshaft sprocket with marking on cylinder head cover. 18. Place toothed belt onto crankshaft sprocket, observe direction of rotation. 19. Install lower toothed belt guard. 20. Install vibration damper/belt pulley with new bolts. Tighten to specification. 21. Turn crankshaft to set cylinder 1 at TDC. 22. Place toothed belt on in this order coolant pump, tensioning roller and camshaft gear. 23. Tension toothed belt as follows: a. If toothed belt tensioner is completely driven out, it must be pressed back by tensioner roller when installed. This procedure can last approximately five minutes. Pressing together with too much force can damage tensioner roller. b. Turn eccentric pulley counterclockwise using tensioning device tool No. 3387, or equivalent, tab (A) of eccentric pulley must not be bent, until tensioning device locking tool No. T10008, or equivalent, can be pulled free of stress, Fig. 13. c. Rotate eccentric pulley clockwise direction of (arrow) until a drill bit (2) with dimension (a) .31 inch, can be pulled through between tensioning lever and housing of tensioning device, Fig. 14. 24. Turn over crankshaft twice and inspect if markings on camshaft and crankshaft still align with their reference points. 25. Inspect dimension (a) .24-.39 inch between tensioning lever and housing of tensioning device using a drill bit (2), Fig. 14. 26. If dimension (a) is not obtained, release tension of toothed belt and tension it again. 27. Install upper and center toothed belt guards. 28. Install tensioner for serpentine belt. Tighten to specification. 29. Install serpentine belt. When installing serpentine belt, ensure that belt is seated correctly in belt pulleys. 30. Place torque wrench tool No. V.A.G 1331, or equivalent, in seven o'clock position and tighten A/C compressor belt tensioner to specification. Hold torque wrench securely and tighten bolts (A) to specification, Fig. 15. 31. Install lock carrier. 32. Install front bumper. 33. Tighten fasteners to specification. 34. Fill cooling system with coolant.

• Fig. 1 Front bumper removal
• Fig. 2 Lock carrier disconnection
• Fig. 3 Lock carrier service position
• Fig. 4 Camshaft sprocket alignment
• Fig. 5 Camshaft drive chain marking location
• Fig. 6 Camshaft drive chain tensioner securing location
• Fig. 7 Camshaft bearing cap removal
• Fig. 8 Camshaft installation
• Fig. 9 Camshaft chain tensioner seal installation
• Fig. 10 Camshaft installation mark alignment
• Fig. 11 Double bearing cap installation
• Fig. 12 Camshaft gear installation
• Fig. 13 Toothed belt tensioning device release
• Fig. 14 Toothed belt tensioning device
• Fig. 15 Air conditioning compressor belt installation

If you want a picture of one of the fig, let me know which one, there are several pictures. All I'm doing is copying out of my database.

There is a Toyota Technical Service Bulletin issued for this:-
T-SB-0291-08 September 11, 2008 2GR-FE Valve Timing

Procedure Service Category Engine/Hybrid System Section Engine Mechanical Market USA Applicability YEAR(S) MODEL(S) ADDITIONAL INFORMATION 2005 - 2009 Avalon 2007 - 2009 Camry VDS(s): BK46K 2008 - 2009 Highlander 2006 - 2009 RAV4 Engine(s): 2GR VDS(s): BK31V, BK32V, BK33V, BK34V, ZK31V, ZK32V, ZK33V, ZK34V, ZK35V 2007 - 2009 Sienna Introduction This service bulletin provides information regarding valve timing inspection and service guidelines for vehicles equipped with 2GR-FE engines. © 2008 Toyota Motor Sales, USA Page 1 of 5 T-SB-0291-08 September 11, 2008 Page 2 of 5 2GR-FE Valve Timing Procedure Introduction (Continued) Figure 1. 3 2 1 5 9 8 7 6 4 1 RH Bank Intake Camshaft Timing Gear 2 RH Bank Exhaust Camshaft Timing Gear 3 RH Bank No. 2 Timing Chain 4 Crankshaft 5 Idler Gear 6 Timing Chain 7 LH Bank No. 2 Timing Chain 8 LH Bank Exhaust Camshaft Timing Gear 9 LH Bank Intake Camshaft Timing Gear Warranty Information OP CODE DESCRIPTION TIME OFP T1 T2 N/A Not Applicable to Warranty © 2008 Toyota Motor Sales, USA T-SB-0291-08 September 11, 2008 Page 3 of 5 2GR-FE Valve Timing Procedure Inspection 1. Set the No. 1 cylinder to TDC/compression. A. Set the timing mark to 0 on the timing chain cover by rotating the crankshaft clockwise. B. Verify the timing marks on the camshaft timing gears are in general alignment with the timing marks of the camshaft bearing cap: TIMING MARK IDENTIFICATION CYLINDER BANK INTAKE GEAR MARK EXHAUST GEAR MARK RH Bank (Bank 1) Small Mark Single Line LH Bank (Bank 2) Large Mark Double Line HINT When the engine is correctly timed, the timing marks will NOT perfectly align. Figure 2. Figure 3. RH Bank Exhaust Camshaft Timing Gear 1 2 1 Bearing Cap Timing Mark 2 Gear Timing Mark Figure 4. RH Bank Intake Camshaft Timing Gear 2 1 1 Bearing Cap Timing Mark 2 Gear Timing Mark © 2008 Toyota Motor Sales, USA T-SB-0291-08 September 11, 2008 Page 4 of 5 2GR-FE Valve Timing Procedure Inspection (Continued) Figure 5. LH Bank Intake Camshaft Timing Gear 1 2 1 Bearing Cap Timing Mark 2 Gear Timing Mark Figure 6. LH Bank Exhaust Camshaft Timing Gear 1 2 1 Bearing Cap Timing Mark 2 Gear Timing Mark HINT If the timing marks appear vastly out of alignment, turn the crankshaft one revolution (360 ) clockwise and note the position of the timing marks. Component Removal Guidelines 1. If engine disassembly is required that involves removing the camshafts or timing gears, set the #1 cylinder to TDC compression, wipe away any oil, and mark the following items in relation to each other prior to disassembly: • Timing gears • Timing chain • Timing chain No. 2 NOTE This relationship MUST be maintained. The intake gear is timed in relation to the crankshaft via the timing chain; the exhaust gear is timed in relation to the intake gear via the No. 2 timing chain. © 2008 Toyota Motor Sales, USA T-SB-0291-08 September 11, 2008 Page 5 of 5 2GR-FE Valve Timing Procedure Component Removal Guidelines (Continued) 2. If NEW camshaft timing gears or the No. 2 timing chain are being installed, the two yellow links on the No. 2 timing chain can be used to ensure correct relationship between the intake timing gear and the exhaust timing gear. Figure 7. 1 1 Yellow Link A. Align the paint mark on the timing chain with the intake gear timing mark (to ensure the intake gear is correctly timed to the crankshaft). Figure 8. RH Bank and LH Bank 3 3 4 3 3 4 5 4 5 4 1 2 1 RH Bank 2 LH Bank 3 Yellow Link 4 Gear Timing Mark 5 Timing Chain Paint Mark B. Align the two yellow links on the No. 2 timing chain to the timing marks on

Timing the Cam to the Crank

There are several ways to time the cam to the crank. Be sure to check the manual before you install the timing chain or belt.

• Some timing sprockets are properly timed when the marks face each other.
• On others, there must be a certain number of chain links between the marks.
• Sometimes chains have colored links that must be aligned with the marks on the sprockets.
• Some overhead cams have a mark on the cam gear that lines up with a mark on the cylinder head when the timing mark on the damper is at the TDC mark.

Align the timing marks for the camshaft and crankshaft sprockets before removing the timing belt or chain.

If the old parts are available, carefully compare the new gears or sprockets with the old ones. Check the keyway and timing marks just in case there might have been an error made in manufacturing. Sprockets are sometimes stamped backward. Its much better to find the problem during assembly, rather than waiting until problems show up after reassembly and reinstallation.

Maintaining Valve Timing

During a valve job, it is essential to keep the timing chain or belt in place to maintain correct valve timing. Position the number one cylinder at TDC. Some overhead cam engines use a single long chain for a cam drive. The chain can be wedged against its guides with a tapered block of wood.
the chain tensioner on some ohc engines must be wedged to keep the chain in position during cylinder head removal. courtesy of nissan motors.

Some engines have a lower and upper chain. These engines do not require special attention to wedging the chain. Be sure to look for hidden head bolts and check the repair manual before removing the OHC head.

Engine timing marks are on the crankshaft pulley.

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.
    

This should be everything you need....

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
    

During most engine rebuilds, a completely new timing assembly should be installed. If wear exists on any component, replacement of the entire assembly is necessary. Wear in the chain, gears, or sprockets means a timing lag, which results in poor engine performance.
The timing chain or belt is generally installed with the gears in their correct positions. Before installing a new chain, soak it in oil.
OHC (Overhead Cam) Engines
Some OHC engines use a chain drive; others use a belt drive. Removing the cover on some OHC engines that have timing chains is more difficult, because the cover often fits between the oil pan and the cylinder head. There are special procedures for replacing cam timing components in these engines.
Before a chain repair job, perform a leakage test on non-freewheeling engines to check for bent valves, so that an accurate repair estimate can be made.
OHV (Overhead Valve) Pushrod Engines
On many OHV pushrod engines, the crankshaft sprocket is installed on the crankshaft nose and the crankshaft is rotated to position piston #1 at TDC. At this point, a mark stamped onto the crankshaft sprocket is pointing directly upward (toward the camshaft).
The camshaft sprocket is then temporarily bolted to the cam and used to rotate the cam until a mark stamped on the cam sprocket is pointing directly downward (toward the crankshaft). The sprocket is then removed from the cam (without allowing the cam to rotate).
The timing chain is looped over the cam gear, the mark on the cam gear is positioned directly downward, and the chain is looped around the crankshaft sprocket. When the cam sprocket is attached to the cam, the timing marks on the crank and cam sprockets should be pointing toward one another. NOTE THIS IS FOR 2WD 4.0

Absolutely NOT TRUE this vehicle has a timing chain, NOT a timing belt. It has a serpentine belt. Thanks for using FIX YA