Aura, Outlook 2007

Timing Chain Cover, Chain, Sprockets, & Seal 2

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Removal & Installation



3.6L Engine
  1. Remove the spark plugs in order to ease crankshaft/engine rotation.
  2.  
  3. Remove the engine front cover as follows:
    1. Remove the lower intake manifold.
    2.  
    3. Remove the camshaft covers.
    4.  
    5. Drain the engine coolant.
    6.  
    7. Remove the drive belt tensioner.
    8.  
    9. Remove the water pump.
    10.  
    11. Remove the power steering pump and position aside.
    12.  
    13. Remove the crankshaft balancer.
    14.  
    15. Remove the camshaft position actuator valves from the front cover.
    16.  
    17. Remove the camshaft position actuator solenoid valves from the front cover.
    18.  
    19. Install the engine support fixture.
    20.  
    21. Install the engine mount bracket.
    22.  
    23. Remove the engine coolant thermostat housing.
    24.  
    25. Remove the engine oil pan.
    26.  
    27. Remove the engine front cover bolts.
    28.  
    29. Loosely install a 10 x 1.5 mm bolt in the "jackscrew" hole (1).
    30.  
    31. Using the pry points (2) located at the edge of the front cover and the "jackscrew", shear the RTV sealant.

      Click image to see an enlarged view

      Fig. Loosely install a 10 x 1.5 mm bolt in the "jackscrew" hole (1). Using the pry points (2) located at the edge of the front cover and the "jackscrew", shear the RTV sealant-3.6L engine

    32.  
    33. Remove the engine front cover. Using the crankshaft rotational socket EN 46111, rotate the crankshaft until the left cylinder head camshafts align with the a camshaft locking tool and the right cylinder head camshafts align with the a camshaft locking tool
    34.  
    35. Install a camshaft locking tool to the right camshafts.
    36.  
    37. Install a camshaft locking tool to the left camshafts.

      Click image to see an enlarged view

      Fig. Install a camshaft locking tool to the right camshafts-3.6L engine



      Click image to see an enlarged view

      Fig. Install a camshaft locking tool to the left camshafts-3.6L engine

    38.  

  4.  
  5. Remove the right bank secondary camshaft drive chain tensioner.
  6.  
  7. Remove the right bank secondary camshaft drive chain shoe.
  8.  
  9. Remove the right bank secondary camshaft drive chain guide.
  10.  
  11. Remove the right secondary camshaft drive chain from the right camshaft position actuators and the right camshaft intermediate drive chain idler sprocket.
  12.  
  13. Remove the primary camshaft drive chain tensioner.
  14.  
  15. Remove the primary camshaft drive chain upper guide.

    Click image to see an enlarged view

    Fig. Secondary camshaft drive chain-3.6L engine



    Click image to see an enlarged view

    Fig. Primary camshaft drive chain-3.6L engine

  16.  
  17. Remove the primary camshaft timing chain.
  18.  
  19. Remove the crankshaft sprocket from the nose of the crankshaft.
  20.  

To install:

Click image to see an enlarged view

Fig. Make sure the crankshaft sprocket is installed with the timing mark (1) visible-3.6L engine

  1. Ensure the crankshaft sprocket is installed with the timing mark (1) visible.
  2.  
  3. Install the crankshaft sprocket on to the nose of the crankshaft.
  4.  
  5. Align the notch in the crankshaft sprocket with the pin in the crankshaft.
  6.  
  7. Slide the crankshaft sprocket on the crankshaft nose until the crankshaft sprocket contacts the step in the crankshaft.

    Click image to see an enlarged view

    Fig. Make sure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) aligned to the stage one timing mark on the oil pump cover (2)-3.6L engine

  8.  
  9. Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) aligned to the stage one timing mark on the oil pump cover (2).
  10.  
  11. Install the primary camshaft timing chain as follows:
    1. Install the primary camshaft drive chain.

      Click image to see an enlarged view

      Fig. Install the primary camshaft drive chain-3.6L engine

    2.  
    3. Wrap the primary camshaft drive chain around the large sprockets of each camshaft intermediate drive chain idler and the crankshaft sprocket.

      Click image to see an enlarged view

      Fig. The left camshaft intermediate drive chain idler timing mark (1) will align with a timing camshaft drive chain link (2)-3.6L engine



      Click image to see an enlarged view

      Fig. The left camshaft intermediate drive chain idler timing mark (1) will align with a timing camshaft drive chain link (2)-3.6L engine

    4.  
    5. The left camshaft intermediate drive chain idler timing mark (1) will align with a timing camshaft drive chain link (2).
    6.  
    7. The right camshaft intermediate drive chain idler timing mark (2) will align with a timing camshaft drive chain link (1).

      Click image to see an enlarged view

      Fig. The right camshaft intermediate drive chain idler timing mark (2) will align with a timing camshaft drive chain link (1)-3.6L engine

    8.  
    9. The crankshaft sprocket timing mark (2) will align with a timing camshaft drive chain link (1).

      Click image to see an enlarged view

      Fig. Ensure all the timing marks (2, 3, 6) are properly aligned with the timing camshaft drive chain links (1, 4, 5)-3.6L engine

    10.  
    11. Ensure all the timing marks (2, 3, 6) are properly aligned with the timing camshaft drive chain links (1, 4, 5).
    12.  

  12.  
  13. Install the primary upper camshaft drive chain guide. Tighten the bolts to 17 ft. lbs. (23 Nm).
  14.  
  15. Install the primary camshaft drive chain tensioner as follows:
    1. Using the tensioner tool J 45027 , reset the primary camshaft drive chain tensioner plunger.

      Click image to see an enlarged view

      Fig. Using the tensioner tool J 45027 , reset the primary camshaft drive chain tensioner plunger-3.6L engine

    2.  
    3. Install the plunger into the primary camshaft drive chain tensioner body.
    4.  
    5. Compress the plunger into the body and lock the primary camshaft drive chain tensioner by inserting the paper clip into the access hole in the side of the primary camshaft drive chain tensioner body.
    6.  
    7. Slowly release pressure on the primary camshaft drive chain tensioner. The primary camshaft drive chain tensioner should remain compressed.
    8.  
    9. Install a NEW primary camshaft drive chain tensioner gasket to the primary camshaft drive chain tensioner.
    10.  
    11. Install the primary camshaft drive chain tensioner bolts through the primary camshaft drive chain tensioner and gasket.
    12.  
    13. Ensure the primary camshaft drive chain tensioner mounting surface on the engine block does not have any burrs or defects that would degrade the sealing of the NEW primary camshaft drive chain tensioner gasket.
    14.  
    15. Place the primary camshaft drive chain tensioner into position and loosely install the bolts to the block.

      Click image to see an enlarged view

      Fig. Verify the proper placement of the primary camshaft drive chain tensioner gasket tab (1)-3.6L engine

    16.  
    17. Verify the proper placement of the primary camshaft drive chain tensioner gasket tab.
    18.  
    19. Tighten the tensioner bolts in two stages. First tighten to 44 in. lbs. (5 Nm) and then to 17 ft. lbs. (23 Nm).
    20.  
    21. Release the primary camshaft drive chain tensioner by pulling out the paper clip and unlocking the tensioner plunger.
    22.  
    23. Verify the primary and left secondary camshaft drive chain timing mark alignments (1-12).

      Click image to see an enlarged view

      Fig. Verify the primary and left secondary camshaft drive chain timing mark alignments (1-12)-3.6L engine

    24.  
    25. Remove the camshaft holding tool from the rear of the left camshafts.
    26.  
    27. Rotate the crankshaft and crankshaft sprocket from the stage 1 alignment position (1) to the stage 2 alignment position (2), 115 crankshaft degrees, in order to install the right secondary camshaft drive chain components.

      Click image to see an enlarged view

      Fig. Rotate the crankshaft and crankshaft sprocket from the stage 1 alignment position (1) to the stage 2 alignment position (2), 115 crankshaft degrees, in order to install the right secondary camshaft drive chain components-3.6L engine

    28.  
    29. Install the camshaft holding tool onto the rear of the left camshafts.
    30.  
    31. Install the camshaft holding tool onto the rear of the right camshafts
    32.  

  16.  
  17. Install the right bank secondary camshaft drive chain as follows:

    Click image to see an enlarged view

    Fig. Ensure that the crankshaft is in the stage 2 timing drive assembly position (1)-3.6L engine

    1. Ensure that the crankshaft is in the stage 2 timing drive assembly position (1).
    2.  
    3. Install the right secondary camshaft drive chain.

      Click image to see an enlarged view

      Fig. Place the secondary camshaft drive chain around the right camshaft intermediate drive chain idler outer sprocket, aligning the timing camshaft drive chain link (1) with the alignment access hole (2) made in the right camshaft intermediate drive chain idler inner sprocket-3.6L engine

    4.  
    5. Place the secondary camshaft drive chain around the right camshaft intermediate drive chain idler outer sprocket, aligning the timing camshaft drive chain link (1) with the alignment access hole (2) made in the right camshaft intermediate drive chain idler inner sprocket.

      Click image to see an enlarged view

      Fig. Wrap the secondary camshaft drive chain around both right actuator drive sprockets. Ensure there are 10 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets-3.6L engine

    6.  
    7. Wrap the secondary camshaft drive chain around both right actuator drive sprockets. Ensure there are 10 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.
    8.  
    9. Align the right exhaust camshaft position actuator sprocket alignment triangle mark (1) with the timing camshaft drive chain link (2).

      Click image to see an enlarged view

      Fig. Align the right exhaust camshaft position actuator sprocket alignment triangle mark (1) with the timing camshaft drive chain link (2)-3.6L engine



      Click image to see an enlarged view

      Fig. Align the right intake camshaft position actuator sprocket alignment triangle mark (2) with the timing camshaft drive chain link (1)-3.6L engine

    10.  
    11. Align the right intake camshaft position actuator sprocket alignment triangle mark (2) with the timing camshaft drive chain link (1).

      Click image to see an enlarged view

      Fig. There will be 22 links (1) between the right camshaft intermediate drive chain idler timing camshaft drive chain link and each right camshaft position actuator sprocket timing camshaft drive chain link-3.6L engine

    12.  
    13. There will be 22 links (1) between the right camshaft intermediate drive chain idler timing camshaft drive chain link and each right camshaft position actuator sprocket timing camshaft drive chain link.
    14.  

  18.  
  19. Install the right bank secondary camshaft drive chain guide. Tighten the bolts to 17 ft. lbs. (23 Nm).
  20.  
  21. Install the right bank secondary camshaft drive chain shoe. Tighten the bolts to 17 ft. lbs. (23 Nm).
  22.  
  23. Install the right bank secondary camshaft drive chain tensioner as follows:
    1. Using the tensioner tool J 45027 , reset the right secondary camshaft drive chain tensioner plunger.
    2.  
    3. Install the plunger into the right secondary camshaft drive chain tensioner body.
    4.  
    5. Compress the plunger into the body and lock the right secondary camshaft drive chain tensioner by inserting a paper clip into the access hole in the side of the right secondary camshaft drive chain tensioner body.
    6.  
    7. Slowly release pressure on the right secondary camshaft drive chain tensioner. The right secondary camshaft drive chain tensioner should remain compressed.
    8.  
    9. Install a NEW right secondary camshaft drive chain tensioner gasket to the right secondary camshaft drive chain tensioner.
    10.  
    11. Install the right secondary camshaft drive chain tensioner bolts through the right secondary camshaft drive chain tensioner and gasket.
    12.  
    13. Ensure the right secondary camshaft drive chain tensioner mounting surface on the right cylinder head does not have any burrs or defects that would degrade the sealing of the NEW right secondary camshaft drive chain tensioner gasket.
    14.  
    15. Place the right secondary camshaft drive chain tensioner into position and loosely install the bolts to the block.

      Click image to see an enlarged view

      Fig. Verify the proper placement of the right secondary camshaft drive chain tensioner gasket tab (1)-3.6L engine

    16.  
    17. Verify the proper placement of the right secondary camshaft drive chain tensioner gasket tab.
    18.  
    19. Tighten the tensioner bolts in two stages. First tighten to 44 in. lbs. (5 Nm) and then to 17 ft. lbs. (23 Nm).
    20.  
    21. Release the right camshaft drive chain tensioner by pulling out the paper clip and unlocking the tensioner plunger.

      Click image to see an enlarged view

      Fig. Verify all primary and secondary camshaft drive chain timing mark alignments (1-18)-3.6L engine

    22.  
    23. Ensure that all timing chain tensioners are completely released. A timing chain tensioner that is not properly released can lead to serious engine damage.
    24.  
    25. Verify all primary and secondary camshaft drive chain timing mark alignments (1-18).
    26.  

  24.  
  25. Install the spark plugs.
  26.  
  27. Install the engine front cove as follows:
    1. Install the 8 mm (0.315 in) guide from a guide pin set such as EN 46109 into the cylinder block positions as shown.

      Click image to see an enlarged view

      Fig. Install the 8 mm (0.315 in) guide from a guide pin set such as EN 46109 into the cylinder block positions-3.6L engine

    2.  
    3. Install the engine front cover to cylinder block seal.
    4.  
    5. Place a 3 mm (0.118 in) bead of RTV sealant, on the engine front cover at points indicated by (1).

      Click image to see an enlarged view

      Fig. Place a 3 mm (0.118 in) bead of RTV sealant, on the engine front cover at points indicated by (1)-3.6L engine

    6.  
    7. Place the engine front cover onto the guide pin set and slide into position.
    8.  
    9. Remove the guide pin set from the cylinder block.
    10.  
    11. Hand start all the front cover bolts.

      Click image to see an enlarged view

      Fig. Front cover fastener torque sequence-3.6L engine

    12.  
    13. Tighten the engine front cover bolts in the sequence show to 17 ft. lbs. (23 Nm).
    14.  
    15. Install the engine oil pan.
    16.  
    17. Install the engine coolant thermostat housing.
    18.  
    19. Reinstall the engine support fixture.
    20.  
    21. Remove the engine mount bracket.
    22.  
    23. Install the camshaft position actuator solenoid valves to the front cover.
    24.  
    25. Install the camshaft position actuator valves to the front cover.
    26.  
    27. Install the crankshaft balancer.
    28.  
    29. Install the power steering pump and position aside.
    30.  
    31. Install the water pump.
    32.  
    33. Install the drive belt tensioner.
    34.  
    35. Install the camshaft covers.
    36.  
    37. Install the lower intake manifold.
    38.  
    39. Refill the engine coolant.
    40.  

  28.  

 
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