Aztek, Rendezvous 2001-2005

Timing Chain Cover, Chain, Sprockets, & Seal 1

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Removal & Installation



3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Crankshaft balancer
     
    Drive belt tensioner
     
    Power steering pump and lines. Do not disconnect the lines from the pump.
     
    Thermostat bypass pipe from the front cover
     
    Radiator outlet hose from the water pump
     
    Water pump pulley
     
    Upper and lower Crankshaft Position (CKP) sensor wire harness bracket from the front cover
     
    CKP sensor from the front cover
     
    Front cover and gasket

    Click image to see an enlarged view

    Fig. Crankshaft timing mark locations-3.4L engine

     

  8.  
  9. Rotate the crankshaft until the timing marks are aligned in the following locations:

    Camshaft alignment pin (1)
     
    Timing chain damper (2) to the crankshaft sprocket (3)
     
    Crankshaft key (4)
     
    Timing chain damper (5) to the camshaft sprocket locator hole (6)
     

  10.  
  11. Remove or disconnect the following:

    Camshaft sprocket bolt
     
    Timing chain, timing chain sprockets and damper
     
    Front oil seal

    Click image to see an enlarged view

    Fig. Exploded view of the timing chain assembly-3.4L engine

     

  12.  

To install:

  1. Install or connect the following:

    New front oil seal by making certain the seal is fully seated
     
    Timing chain damper. Torque the bolts to 15 ft. lbs. (21 Nm).
     
    Timing chain to the camshaft sprocket
     
    Crankshaft sprocket
     
    Timing chain to the crankshaft sprocket by making certain the chain is fully seated
     

  2.  
  3. Align the crankshaft timing mark to the bottom mark on the damper.
  4.  
  5. Align the timing mark on the camshaft gear center line of the locator hole with the timing mark on the top of the damper.
  6.  
  7. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
  8.  
  9. Install or connect the following:

    Camshaft sprocket bolt. Torque the bolt to 103 ft. lbs. (140 Nm).
     

  10.  
  11. Apply a 0.20 inch (5mm) bead of sealer to both sides of the lower tabs of the engine front cover gasket.

    Front cover. Refer to the accompanying figure and torque bolts (2) to 15 ft. lbs. (21 Nm), bolts (3) to 41 ft. lbs. (55 Nm) and bolts (1) to 35 ft. lbs. (47 Nm).

    Click image to see an enlarged view

    Fig. Timing chain front cover bolt tightening specifications-3.4L engine

     
    Water pump to the front cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Water pump pulley. Torque the bolt to 18 ft. lbs. (25 Nm).
     
    CKP sensor to the front cover
     
    Upper/lower CKP wire harness brackets to the front cover
     
    Radiator outlet hose to the water pump
     
    Thermostat bypass pipe to the front cover
     
    Power steering pump and lines
     
    Drive belt tensioner
     
    Crankshaft balancer
     
    Negative battery cable
     

  12.  
  13. Fill the engine with oil.
  14.  
  15. Fill the coolant system.
  16.  
  17. Start the vehicle and verify that the engine is running properly.
  18.  

3.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the engine/transaxle assembly.
  4.  
  5. Remove the alternator, power steering pump and A/C compressor.
  6.  
  7. Remove the crankshaft balancer.
  8.  
  9. Remove the camshaft position actuator valve bolts.
  10.  
  11. Remove the camshaft position actuator valves from the front cover.
  12.  
  13. Remove the engine front cover bolts.
    NOTE
    Do not pry between the engine front cover and the camshaft position sensors or the camshaft position actuators in order to shear the RTV. Use the pry points and a bolt in the jackscrew hole in order to remove the engine front cover. Damage to the camshaft position sensors or the camshaft position actuators may occur if the camshaft position sensors or the camshaft position actuators are used to pry against in order to remove the engine front cover.



    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

  14.  
  15. Loosely install a 10 x 1.5 mm bolt in the "jackscrew" hole (1).
  16.  
  17. Using the pry points (2) located at the edge of the front cover and the "jackscrew", shear the RTV sealant.
  18.  
  19. Remove the engine front cover.
  20.  
  21. Using tool EN 46111 , rotate the crankshaft until the left cylinder head camshafts align with tool EN 46105-2 and the right cylinder head camshafts align with tool EN 46105-1.
  22.  
  23. Install tool EN 46105-1 to the right camshafts.
  24.  
  25. Install tool EN 46105-2 to the left camshafts.
  26.  
  27. Remove the right secondary camshaft drive chain tensioner bolts.
  28.  
  29. Remove the right secondary camshaft drive chain tensioner.
  30.  
  31. Remove and discard the right secondary camshaft drive chain tensioner gasket.
  32.  
  33. Inspect the right secondary camshaft drive chain tensioner mounting surface on the right cylinder head for burrs or any defects that would degrade the sealing of the NEW right secondary camshaft drive chain tensioner gasket.
  34.  
  35. Remove the right secondary camshaft drive chain shoe bolt.
  36.  
  37. Remove the right secondary camshaft drive chain shoe.
  38.  
  39. Remove the right secondary camshaft drive chain guide bolts.
  40.  
  41. Remove the right secondary camshaft drive chain guide.
  42.  
  43. Remove the right secondary camshaft drive chain from the right camshaft position actuators and the right camshaft intermediate drive chain idler sprocket.
  44.  
  45. Remove the primary camshaft drive chain tensioner bolts.
  46.  
  47. Remove the primary camshaft drive chain tensioner.
  48.  
  49. Remove and discard the primary camshaft drive chain tensioner gasket.
  50.  
  51. Inspect the primary camshaft drive chain tensioner mounting surface on the engine block for burrs or any defects that would degrade the sealing of the NEW primary camshaft drive chain tensioner gasket.
  52.  
  53. Remove the primary camshaft drive chain upper guide bolts.
  54.  
  55. Remove the primary camshaft drive chain upper guide.
    NOTE
    Do not remove the primary camshaft drive chain lower guide. The primary camshaft drive chain lower guide is not serviceable separately. If the primary camshaft drive chain lower guide must be replaced, the oil pump must be replaced.

  56.  
  57. Remove the primary camshaft drive chain.
  58.  
  59. Remove the right camshaft intermediate drive chain idler bolt.
  60.  
  61. Remove the right camshaft intermediate drive chain idler.
  62.  
  63. Remove the left secondary camshaft drive chain tensioner bolts.
  64.  
  65. Remove the left secondary camshaft drive chain tensioner.
  66.  
  67. Remove and discard the left secondary camshaft drive chain tensioner gasket.
  68.  
  69. Inspect the left secondary camshaft drive chain tensioner mounting surface on the left cylinder head for burrs or any defects that would degrade the sealing of the NEW left secondary camshaft drive chain tensioner gasket.
  70.  
  71. Remove the left secondary camshaft drive chain shoe bolt.
  72.  
  73. Remove the left secondary camshaft drive chain shoe.
  74.  
  75. Remove the left secondary camshaft drive chain guide bolts.
  76.  
  77. Remove the left secondary camshaft drive chain guide.
  78.  
  79. Remove the left secondary camshaft drive chain from the left camshaft position actuators and the left camshaft intermediate drive chain idler sprocket.
  80.  
  81. Remove the left camshaft intermediate drive chain idler bolt.
  82.  
  83. Remove the left camshaft intermediate drive chain idler.
  84.  
  85. Remove the crankshaft sprocket from the nose of the crankshaft.
    NOTE
    Use an open wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt.

  86.  
  87. Remove the left exhaust camshaft position actuator bolt.
  88.  
  89. Remove the left exhaust camshaft position actuator.
    NOTE
    A wrench must be used on the hex of the camshaft when loosening or tightening in order to prevent component damage. Failure to prevent the torque reaction against the timing drive chain can lead to timing drive chain failure.

  90.  
  91. Use an open wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt.
  92.  
  93. Remove the left intake camshaft position actuator bolt.
  94.  
  95. Remove the left intake camshaft position actuator.
    NOTE