Aura, Outlook 2007

Timing Chain Cover, Chain, Sprockets, & Seal 1

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Removal & Installation



2.4L Engine
  1. Remove the No. 1 cylinder spark plug.
  2.  
  3. Rotate the crankshaft in the engine rotational direction clockwise, until the No. 1 piston is at Top Dead Center (TDC) on the compression stroke.
  4.  
  5. Remove the camshaft cover.
  6.  
  7. Remove the engine front cover as follows:
    1. Remove the drive belt tensioner.
    2.  
    3. Remove the crankshaft balancer.
    4.  
    5. Install the engine support fixture.
    6.  
    7. Remove the engine mount to bracket bolts.
    8.  
    9. Remove the engine mount to side rail nuts.
    10.  
    11. Remove the engine mount from the engine compartment.
    12.  
    13. Remove the engine mount bracket to engine bolts.
    14.  
    15. Remove the engine mount bracket.
    16.  
    17. Remove the engine front cover to water pump bolt.
    18.  
    19. Raise and suitably support the vehicle.
    20.  
    21. Remove the engine front cover bolts.
    22.  
    23. Remove the engine front cover.
    24.  
    25. Remove and discard the engine front cover gasket.
    26.  

  8.  
  9. Remove the upper timing chain guide bolts and guide.
    NOTE
    The timing chain tensioner must be removed to unload chain tension before the timing chain is removed. If it is not, the timing chain will become cocked and it will be difficult to remove.

  10.  
  11. Remove the timing chain tensioner.

    Click image to see an enlarged view

    Fig. Remove and discard the exhaust camshaft actuator bolt (2). Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain -2.4L engine

  12.  
  13. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
  14.  
  15. Remove and discard the exhaust camshaft actuator bolt.
  16.  
  17. Remove the exhaust camshaft actuator from the camshaft and timing chain.
  18.  
  19. Remove the timing chain tensioner guide bolt and guide.
  20.  
  21. Remove the fixed timing chain guide access plug.
  22.  
  23. Remove the fixed timing chain guide bolts and guide.

    Click image to see an enlarged view

    Fig. Remove and discard the intake camshaft actuator bolt (2). Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head-2.4L engine

  24.  
  25. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
  26.  
  27. Remove and discard the intake camshaft actuator bolt.
  28.  
  29. Remove the intake camshaft actuator, and the timing chain through the top of the cylinder head.
  30.  
  31. Remove the timing chain crankshaft sprocket.
  32.  
  33. If replacing the balance shaft timing chain and sprocket, perform the following:
    1. Remove the balance shaft drive chain tensioner bolts and tensioner.
    2.  
    3. Remove the adjustable balance shaft chain guide bolt and guide.
    4.  
    5. Remove the small balance shaft drive chain guide bolts and guide.
    6.  
    7. Remove the upper balance shaft drive chain guide bolts and guide.
      NOTE
      It may ease removal of the balance shaft drive chain to get all the slack in the chain between the crankshaft and water pump sprockets.

    8.  

  34.  
  35. Remove the balance shaft drive chain.
  36.  
  37. Remove the balance shaft drive sprocket .
  38.  

To install:

  1. If replacing the balance shaft timing chain, perform the following:
    1. Install the balance shaft drive sprocket.
      NOTE
      If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise.

    2.  
    3. Install the balance shaft drive chain with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and 1 is copper.
    4.  
    5. Use the following steps in order to line up the links with the sprockets:

      Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket.
       
      Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket).
       
      Place the chain (7) on the water pump drive sprocket. The alignment is not critical Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.

      Click image to see an enlarged view

      Fig. Balance shaft drive chain components-2.4L engine

       

    6.  
    7. Install the upper balance shaft drive chain guide and bolts and tighten to 11 ft. lbs. (15 Nm).
    8.  
    9. Install the small balance shaft drive chain guide and bolts and tighten to 11 ft. lbs. (15 Nm).
    10.  

  2.  
  3. Install the adjustable balance shaft chain guide and bolt and tighten to 89 in. lbs. (10 Nm).
  4.  
  5. Reset the timing chain tensioner by performing the following:
    1. Rotate the tensioner plunger 90 degrees in its bore and compress the plunger
    2.  
    3. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
    4.  
    5. Install the balance shaft drive chain tensioner and bolt and tighten to 89 in. lbs. (10 Nm).
    6.  
    7. Remove the paper clip from the balance shaft drive chain tensioner.

      Click image to see an enlarged view

      Fig. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock-2.4L engine

    8.  

  6.  
  7. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.

    Click image to see an enlarged view

    Fig. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out-2.4L engine

  8.  
  9. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
    NOTE
    There are 3 colored links on the timing chain. Two links are of matching color, and 1 link is of a unique color. Use the following procedure to line up the links with the actuators. Orient the chain so that the colored links are visible. Always use new actuator bolts.



    Click image to see an enlarged view

    Fig. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1)-2.4L engine

  10.  
  11. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link.

    Click image to see an enlarged view

    Fig. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2)-2.4L engine

  12.  
  13. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
  14.  
  15. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
  16.  
  17. Hand tighten the new intake camshaft actuator bolt.

    Click image to see an enlarged view

    Fig. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position-2.4L engine

  18.  
  19. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
  20.  
  21. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
  22.  
  23. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt and tighten to 89 in. lbs. (10 Nm).
    NOTE
    Always install NEW actuator bolts.

  24.  
  25. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.

    Click image to see an enlarged view

    Fig. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link-2.4L engine

  26.  
  27. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
  28.  
  29. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
  30.  
  31. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
  32.  
  33. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks

    Click image to see an enlarged view

    Fig. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks-2.4L engine

  34.  
  35. Install the fixed timing chain guide and bolts and tighten to 106 in. lbs. (12 Nm).
  36.  
  37. Install the upper timing chain guide and bolts and tighten to 89 in. lbs. (10 Nm).
  38.  
  39. Reset the timing chain tensioner by performing the following:
    1. Remove the snap ring.
    2.  
    3. Remove the piston assembly from the body of the timing chain tensioner.
    4.  
    5. Install tensioner tool J 45027-2 (2) into a vise.
    6.  
    7. Install the notch end of the piston assembly into the tool.
    8.  
    9. Using the J 45027-1 handle (1), turn the ratchet cylinder into the piston.
    10.  
    11. Reinstall the piston assembly into the body of the tensioner.
    12.  
    13. Install the snap ring.

      Click image to see an enlarged view

      Fig. Install tensioner tool J 45027-2 (2) into a vise, Install the notch end of the piston assembly into the tool and using the J 45027-1 handle (1), turn the ratchet cylinder into the piston-2.4L engine

    14.  

  40.  
  41. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
  42.  
  43. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
    NOTE
    Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak.

  44.  
  45. Install the timing chain tensioner assembly.
  46.  
  47. Tighten the timing chain tensioner to 55 ft. lbs. (75 Nm).
    NOTE
    The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet.

  48.  
  49. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
  50.  
  51. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt.
  52.  
  53. Tighten the intake camshaft position actuator bolt to 22 ft. lbs. (30 Nm), plus an additional 100 degrees.
  54.  
  55. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt.
  56.  
  57. Tighten the exhaust camshaft position actuator bolt to 22 ft. lbs. (30 Nm), plus an additional 100 degrees.
  58.  
  59. Install the timing chain oiling nozzle and bolt and tighten to 89 in. lbs. (10 Nm).
  60.  
  61. Apply sealant compound to the thread of the timing chain guide bolt access hole plug.
  62.  
  63. Install the timing chain guide bolt access hole plug and tighten to 66 ft. lbs. lbs. (90 Nm).
  64.  
  65. Install the engine front cover as follows:
    1. Install a NEW engine front cover gasket to the dowel pins.
    2.  
    3. Install the engine front cover.
    4.  
    5. Install the engine front cover bolts and tighten to 18 ft. lbs. (25 Nm).
    6.  
    7. Lower the vehicle.
    8.  
    9. Install the engine front cover to water pump bolt and tighten to 18 ft. lbs. (25 Nm).
    10.  
    11. Position the engine mount bracket to the engine.
    12.  
    13. Install the engine mount bracket bolts in the following locations:

      The long bolts in the forward and lower rear holes
       
      The short bolt in the upper rear hole
       

    14.  
    15. Tighten the engine mount bracket bolts to 74 ft. lbs. (100 Nm) in the following sequence.

      Upper left
       
      Lower left
       
      Right
       

    16.  
    17. Install the engine mount to the engine compartment.
    18.  
    19. Install the engine mount to side rail nuts and tighten to 74 ft. lbs. (100 Nm)
    20.  
    21. Install the engine mount to bracket bolts.
    22.  
    23. Tighten the engine mount to bracket bolts to 37 ft. lbs. (50 Nm) in the following sequence.

      Middle
       
      Rear
       
      Front
       

    24.  
    25. Remove the engine support fixture.
    26.  
    27. Install the crankshaft balancer.
    28.  
    29. Install the drive belt tensioner.
    30.  

  66.  
  67. Install the camshaft cover.
  68.  
  69. Install the No. 1 cylinder spark plug.
  70.  

3.5L Engine
  1. Remove the engine front cover as follows:
    1. Drain the cooling system.
    2.  
    3. Remove the drive belt tensioner.
    4.  
    5. Remove the oil pan.
    6.  
    7. Remove the crankshaft balancer.
    8.  
    9. Remove the crankshaft position actuator magnet.
    10.  
    11. Remove the thermostat housing.
    12.  
    13. Remove the water pump.
    14.  
    15. Remove the engine front cover bolts.
    16.  
    17. Remove the engine front cover.
    18.  
    19. Remove the engine front cover gasket.

      Click image to see an enlarged view

      Fig. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2). Align the timing mark on the camshaft position actuator gear (4) with the timing mark on top of the timing chain tensioner (3)-3.5L engine

    20.  

  2.  
  3. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2). Refer to the illustration for mark locations.
  4.  
  5. Align the timing mark on the camshaft position actuator gear (4) with the timing mark on top of the timing chain tensioner (3). Refer to the illustration for mark locations.
  6.  
  7. Remove the camshaft position actuator bolts.
  8.  
  9. Remove the timing chain, camshaft position actuator, and crankshaft sprockets.
  10.  
  11. Remove the timing chain tensioner bolts.
  12.  
  13. Remove the timing chain tensioner.
  14.  
  15. Remove the crankshaft sprocket.
  16.  
  17. Remove the timing chain dampener bolts.
  18.  
  19. Remove the timing chain dampener.

    Click image to see an enlarged view

    Fig. Remove and discard the camshaft position actuator filter (1) from the end of the camshaft-3.5L engine

  20.  
  21. Remove and discard the camshaft position actuator filter from the end of the camshaft.
    NOTE
    Always install a NEW camshaft position actuator filter anytime the camshaft actuator is removed.

  22.  

To install:

  1. Install a NEW the camshaft position actuator filter to the end of the camshaft.
  2.  
  3. Install the crankshaft sprocket.
  4.  
  5. Apply prelube to the crankshaft sprocket thrust surface.
  6.  
  7. Install the timing chain tensioner. Tighten the bolts to 15 ft. lbs. (21 Nm).

    Click image to see an enlarged view

    Fig. Use tensioner compressor EN-47719 fully collapse the tensioner, and place he tensioner retaining pin into the retaining hole (1)-3.5L engine



    Click image to see an enlarged view

    Fig. (1)Crankshaft timing mark (2)Timing chain tensioner bottom timing mark (3)Camshaft position actuator gear timing mark (4)Timing chain tensioner top timing mark -3.5L engine

  8.  
  9. Use tensioner compressor EN-47719 , fully collapse the tensioner, and place he tensioner retaining pin into the retaining hole.
  10.  
  11. Align the crankshaft timing mark to the timing mark on the bottom of the timing chain tensioner.
  12.  
  13. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
  14.  
  15. Align the timing mark on the camshaft position actuator gear with the timing mark on top of the timing chain tensioner.
  16.  
  17. Align the dowel in the camshaft position actuator with the dowel hole in the camshaft.
  18.  
  19. Install the camshaft position actuator bolts.
    NOTE
    Use only a Torx Plus Bit when removing or installing the camshaft position actuator fasteners. The Torx Plus design differs from typical Torx fastener. Use of a standard Torx bit on Torx Plus fasteners may result in a rounded out fastener head or incorrect faster torque.


    NOTE
    DO NOT use any type of threadlocking compound on the camshaft position actuator bolts. Usage of a threadlocking compound on the threads could lead to contamination of the camshaft position actuator, possibly resulting in potential damage to the actuator.

  20.  
  21. Draw the camshaft actuator onto the camshaft using the bolts. Tighten op 12 ft. lbs. (16 Nm).
  22.  
  23. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
  24.  
  25. Coat the crankshaft and camshaft sprockets with clean engine oil.
  26.  
  27. Install the engine front cover as follows:
    1. Install the engine front cover gasket.
    2.  
    3. Install the engine front cover.
    4.  
    5. Apply sealant to the bolts in the locations pointed out in the illustration.

      Click image to see an enlarged view

      Fig. Apply sealant to the bolts in the locations pointed out by the number (1)-3.5L engine

    6.  
    7. Install the engine front cover bolts. Tighten to 18 ft. lbs. (25 Nm).
    8.  
    9. Install the water pump.
    10.  
    11. Install the thermostat housing.
    12.  
    13. Install the crankshaft position actuator magnet.
    14.  
    15. Install the crankshaft balancer.
    16.  
    17. Install the oil pan. Install the drive belt tensioner.
    18.  
    19. Fill the cooling system.
    20.  

  28.  

 
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