Aztek, Rendezvous 2001-2005

Timing Chain Cover, Chain, Sprockets, & Seal 2

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Removal & Installation



3.6L Engine
  1. Observe the body of the camshaft position actuator for the "IN" marking (3). The marking is for an intake camshaft position actuator.
  2.  
  3. Ensure the proper timing mark is used. Observe the outer ring of the camshaft position actuator for the "R" and triangle marking (2). The marking is for alignment to the highlighted timing chain link on the right side of the engine.
  4.  
  5. Use an open wrench on the hex cast into the camshaft in order to prevent camshaft rotation when tightening the camshaft position actuator bolt.
  6.  
  7. Install the right intake camshaft position actuator.
  8.  
  9. Install the camshaft position actuator bolt. Tighten the camshaft position actuator bolt to 43 ft. lbs. (58 Nm).
  10.  
  11. Observe the body of the camshaft position actuator for the "EX" marking (1). The marking is for an exhaust camshaft position actuator.
  12.  
  13. Ensure the proper timing mark is used. Observe the outer ring of the camshaft position actuator for the "R" and triangle marking (2). The marking is for alignment to the highlighted timing chain link on the right side of the engine.
    NOTE
    Use an open wrench on the hex cast into the camshaft in order to prevent camshaft rotation when tightening the camshaft position actuator bolt.

  14.  
  15. Install the right exhaust camshaft position actuator.
  16.  
  17. Install the camshaft position actuator bolt. Tighten the camshaft position actuator bolt to 43 ft. lbs. (58 Nm).
  18.  
  19. Observe the body of the camshaft position actuator for the "IN" marking (3). The marking is for an intake camshaft position actuator.
  20.  
  21. Ensure the proper timing mark is used. Observe the outer ring of the camshaft position actuator for the "L" and circle marking (1). The marking is for alignment to the highlighted timing chain link on the left side of the engine.
    NOTE
    Use an open wrench on the hex cast into the camshaft in order to prevent camshaft rotation when tightening the camshaft position actuator bolt.

  22.  
  23. Install the left intake camshaft position actuator.
  24.  
  25. Install the camshaft position actuator bolt. Tighten the camshaft position actuator bolt to 43 ft. lbs. (58 Nm).
  26.  
  27. Observe the body of the camshaft position actuator for the "EX" marking (1). The marking is for an exhaust camshaft position actuator.
  28.  
  29. Ensure the proper timing mark is used. Observe the outer ring of the camshaft position actuator for the "L" and circle marking (3). The marking is for alignment to the highlighted timing chain link on the left side of the engine.
    NOTE
    Use an open wrench on the hex cast into the camshaft in order to prevent camshaft rotation when tightening the camshaft position actuator bolt.

  30.  
  31. Install the left exhaust camshaft position actuator.
  32.  
  33. Install the camshaft position actuator bolt. Tighten the camshaft position actuator bolt to 43 ft. lbs. (58 Nm).
  34.  
  35. Ensure the crankshaft sprocket is installed with the timing mark (1) visible. Install the crankshaft sprocket on to the nose of the crankshaft.
  36.  
  37. Align the notch in the crankshaft sprocket with the pin in the crankshaft.

    Click image to see an enlarged view

    Fig. Crankshaft sprocket-3.6L engine

  38.  
  39. Slide the crankshaft sprocket on the crankshaft nose until the crankshaft sprocket contacts the step in the crankshaft.
  40.  
  41. If necessary, align the crankshaft sprocket to the stage one timing drive assembly position using tool EN 46111.

    Click image to see an enlarged view

    Fig. Ensure that the crankshaft is in the stage one timing drive assembly position using the EN 46111-3.6L engine



    Click image to see an enlarged view

    Fig. Left camshaft intermediate drive chain idler-3.6L engine

  42.  
  43. The recessed hub (3) and the larger sprocket of the left camshaft intermediate drive chain idler is installed outward. The raised hub and the smaller sprocket of the left camshaft intermediate drive chain idler is installed towards the block. Place the left camshaft intermediate drive chain idler to the cylinder block.
  44.  
  45. Install the camshaft intermediate drive chain idler bolt. Tighten the camshaft intermediate drive chain idler bolt to 43 ft. lbs. (58 Nm).
    WARNING
    There should be no need to rotate the camshaft more than 10 degrees. Using the hex cast into the camshaft rotate the camshaft in order to install tool EN 46105.

  46.  
  47. Install tool EN 46105-1 onto the rear of the left camshafts.
    WARNING
    All camshafts must be locked in place before installation of any camshaft drive chains.

  48.  
  49. Ensure that tool EN 46105-1 is fully seated onto the camshafts.
  50.  
  51. Ensure that the crankshaft is in the stage one timing drive assembly position using tool EN 46111.
  52.  
  53. Install the left secondary camshaft drive chain.

    Click image to see an enlarged view

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

  54.  
  55. Place the left secondary camshaft drive chain around the inner sprocket of the left camshaft intermediate drive chain idler with the timing camshaft drive chain link (1) aligned to the alignment access hole (2) made in the left camshaft intermediate drive chain idler outer sprocket. Wrap the secondary camshaft drive chain around both left actuator drive sprockets.

    Click image to see an enlarged view

    Fig. Ensure there are 7 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets-3.6L engine

  56.  
  57. Ensure there are 7 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.

    Click image to see an enlarged view

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

  58.  
  59. Align the left exhaust camshaft position actuator sprocket alignment circle mark (2) with the timing camshaft drive chain link (1).

    Click image to see an enlarged view

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

  60.  
  61. Align the left intake camshaft position actuator sprocket alignment circle mark (1) with the timing camshaft drive chain link (2).

    Click image to see an enlarged view

    Fig. There will be 18 links (1) between the left camshaft intermediate drive chain idler timing secondary camshaft drive chain link and each left camshaft position actuator sprocket timing secondary camshaft drive chain link-3.6L engine

  62.  
  63. There will be 18 links (1) between the left camshaft intermediate drive chain idler timing secondary camshaft drive chain link and each left camshaft position actuator sprocket timing secondary camshaft drive chain link.
  64.  
  65. Position the left secondary camshaft drive chain guide.
  66.  
  67. Install the secondary camshaft drive chain guide bolts. Tighten the secondary camshaft drive chain guide bolts to 17 ft. lbs. (23 Nm).
  68.  
  69. Position the left secondary camshaft drive chain shoe.
  70.  
  71. Install the secondary camshaft drive chain shoe bolt. Tighten the secondary camshaft drive chain shoe bolt to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

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

  72.  
  73. Using tool J 45027 reset the left secondary camshaft drive chain tensioner plunger.
  74.  
  75. Install the plunger into the left secondary camshaft drive chain tensioner body.
  76.  
  77. Compress the plunger into the body and lock the left secondary camshaft drive chain tensioner by inserting tool EN 46112 into the access hole in the side of the left secondary camshaft drive chain tensioner body.
  78.  
  79. Slowly release pressure on the left secondary camshaft drive chain tensioner. The left secondary camshaft drive chain tensioner should remain compressed.
  80.  
  81. Install a NEW left secondary camshaft drive chain tensioner gasket to the left secondary camshaft drive chain tensioner.
  82.  
  83. Install the left secondary camshaft drive chain tensioner bolts through the left secondary camshaft drive chain tensioner and gasket.
  84.  
  85. Ensure the left secondary camshaft drive chain tensioner mounting surface on the left cylinder head does not have any burrs or defects that would degrade the sealing of the NEW left secondary camshaft drive chain tensioner gasket.
  86.  
  87. Place the left 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 left secondary camshaft drive chain tensioner gasket tab (1)-3.6L engine

  88.  
  89. Verify the proper placement of the left secondary camshaft drive chain tensioner gasket tab (1).

    First Pass: Tighten the left secondary camshaft drive chain tensioner bolts to 44 inch lbs. (5 Nm).
     
    Final Pass: Tighten the left secondary camshaft drive chain tensioner bolts to 17 ft. lbs. (23 Nm).
     

  90.  
  91. Release the left secondary camshaft drive chain tensioner by pulling out tool EN 46112 and unlocking the tensioner plunger.
  92.  
  93. Verify the left secondary camshaft drive chain timing mark alignments (1-6). Ensure that the right camshaft intermediate drive chain idler (1) is being installed. The recessed hub (4) and the smaller sprocket of the right camshaft intermediate drive chain idler is installed outward. The raised hub and the larger sprocket of the right camshaft intermediate drive chain idler is installed towards the block.
  94.  
  95. Install the right camshaft intermediate drive chain idler.
  96.  
  97. Install the camshaft intermediate drive chain idler bolt. Tighten the camshaft intermediate drive chain idler bolt to 43 ft. lbs. (58 Nm).
    NOTE
    Ensure that the crankshaft is in the stage one timing drive assembly position.

  98.  
  99. Install the primary camshaft drive chain.

    Click image to see an enlarged view

    Fig. Wrap the primary camshaft drive chain around the large sprockets of each camshaft intermediate drive chain idler and the crankshaft sprocket-3.6L engine

  100.  
  101. 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

  102.  
  103. The left camshaft intermediate drive chain idler timing mark (1) will align with a timing camshaft drive chain link (2).

    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

  104.  
  105. 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 crankshaft sprocket timing mark (2) will align with a timing camshaft drive chain link (1)-3.6L engine

  106.  
  107. 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

  108.  
  109. Ensure all the timing marks (2, 3, 6) are properly aligned with the timing camshaft drive chain links (1, 4, 5).
  110.  
  111. Install the primary camshaft drive chain upper guide.
  112.  
  113. Install the primary camshaft drive chain upper guide bolts. Tighten the primary camshaft drive chain upper guide bolts to 17 ft. lbs. (23 Nm).
  114.  
  115. Using tool J 45027 reset the primary camshaft drive chain tensioner plunger.
  116.  
  117. Install the plunger into the primary camshaft drive chain tensioner body.

    Click image to see an enlarged view

    Fig. Compress the plunger into the body and lock the primary camshaft drive chain tensioner by inserting tool EN 46112 into the access hole in the side of the primary camshaft drive chain tensioner body-3.6L engine

  118.  
  119. Compress the plunger into the body and lock the primary camshaft drive chain tensioner by inserting tool EN 46112 into the access hole in the side of the primary camshaft drive chain tensioner body.
  120.  
  121. Slowly release pressure on the primary camshaft drive chain tensioner. The primary camshaft drive chain tensioner should remain compressed.
  122.  
  123. Install a NEW primary camshaft drive chain tensioner gasket to the primary camshaft drive chain tensioner.
  124.  
  125. Install the primary camshaft drive chain tensioner bolts through the primary camshaft drive chain tensioner and gasket.
  126.  
  127. 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.
  128.  
  129. 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

  130.  
  131. Verify the proper placement of the primary camshaft drive chain tensioner gasket tab (1).

    First Pass: Tighten the primary camshaft drive chain tensioner bolts to 44 inch lbs. (5 Nm).
     
    Final Pass: Tighten the primary camshaft drive chain tensioner bolts to 17 ft. lbs. (23 Nm).
     

  132.  
  133. Release the primary camshaft drive chain tensioner by pulling out tool EN 46112 and unlocking the tensioner plunger.

    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

  134.  
  135. Verify the primary and left secondary camshaft drive chain timing mark alignments (1-12).
  136.  
  137. Remove tool EN 46105-1 from the rear of the left camshafts.
  138.  
  139. Using tool EN 46111 rotate the crankshaft and crankshaft sprocket from the stage one alignment position (1) to the stage two alignment position (2), 115 crankshaft degrees, in order to install the right secondary camshaft drive chain components.
  140.  
  141. Install tool EN 46105-2 onto the rear of the left camshafts.
  142.  
  143. Install tool EN 46105-1 onto the rear of the right camshafts.
  144.  
  145. Ensure that the crankshaft is in the stage two timing drive assembly position.
  146.  
  147. 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

  148.  
  149. 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.
  150.  
  151. Wrap the secondary camshaft drive chain around both right actuator drive sprockets.

    Click image to see an enlarged view

    Fig. Ensure there are 7 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets-3.6L engine

  152.  
  153. Ensure there are 7 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.

    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

  154.  
  155. 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 intake camshaft position actuator sprocket alignment triangle mark (2) with the timing camshaft drive chain link (1)-3.6L engine

  156.  
  157. 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 18 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

  158.  
  159. There will be 18 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.
  160.  
  161. Position the right secondary camshaft drive chain guide.
  162.  
  163. Install the secondary camshaft drive chain guide bolts. Tighten the secondary camshaft drive chain guide bolts to 17 ft. lbs. (23 Nm).
  164.  
  165. Position the right secondary camshaft drive chain shoe.
  166.  
  167. Install the secondary camshaft drive chain shoe bolt. Tighten the secondary camshaft drive chain shoe bolt to 17 ft. lbs. (23 Nm).
  168.  
  169. Using tool J 45027 reset the right secondary camshaft drive chain tensioner plunger.
  170.  
  171. Install the plunger into the right secondary camshaft drive chain tensioner body.
  172.  
  173. Compress the plunger into the body and lock the right secondary camshaft drive chain tensioner by inserting tool EN 46112 into the access hole in the side of the right secondary camshaft drive chain tensioner body.
  174.  
  175. Slowly release pressure on the right secondary camshaft drive chain tensioner. The right secondary camshaft drive chain tensioner should remain compressed.
  176.  
  177. Install a NEW right secondary camshaft drive chain tensioner gasket to the right secondary camshaft drive chain tensioner.
  178.  
  179. Install the right secondary camshaft drive chain tensioner bolts through the right secondary camshaft drive chain tensioner and gasket.
  180.  
  181. 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.
  182.  
  183. Place the right secondary camshaft drive chain tensioner into position and loosely install the bolts to the block.
  184.  
  185. Verify the proper placement of the right secondary camshaft drive chain tensioner gasket tab (1).

    First Pass: Tighten the right secondary camshaft drive chain tensioner bolts to 44 inch lbs. (5 Nm).
     
    Final Pass: Tighten the right secondary camshaft drive chain tensioner bolts to 17 ft. lbs. (23 Nm).
     

  186.  
  187. Release the right camshaft drive chain tensioner by pulling out tool EN 46112 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) Stage Two-3.6L engine

  188.  
  189. Verify all primary and secondary camshaft drive chain timing mark alignments (1-18) Stage Two.

    Click image to see an enlarged view

    Fig. Install the 8mm (0.315 in) guide pins from tool EN 46109 into the cylinder block positions as shown-3.6L engine

  190.  
  191. Install the 8mm (0.315 in) guide pins from tool EN 46109 into the cylinder block positions as shown.

    Click image to see an enlarged view

    Fig. Install the NEW engine front cover to cylinder block seal-3.6L engine

  192.  
  193. Install the NEW engine front cover to cylinder block seal.

    Click image to see an enlarged view

    Fig. Place a 3mm (0.118 in) bead of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover as shown (1)-3.6L engine

  194.  
  195. Place a 3mm (0.118 in) bead of RTV sealant, GM P/N 12378521 (Canadian P/N 88901148) or equivalent, on the engine front cover as shown (1).
  196.  
  197. Place the engine front cover onto tool EN 46109 and slide into position.
  198.  
  199. Remove tool EN 46109 from the cylinder block.
  200.  
  201. Hand start all the front cover bolts.

    Click image to see an enlarged view

    Fig. Tighten the engine front cover bolts in the sequence shown-3.6L engine

  202.  
  203. Tighten the engine front cover bolts in the sequence shown. Tighten the engine front cover bolts in sequence to 17 ft. lbs. (23 Nm).
  204.  
  205. Install NEW O-rings on the camshaft position sensor.
  206.  
  207. Place the camshaft position sensors in position on the front cover.
  208.  
  209. Install the camshaft position sensor bolts. Tighten the camshaft position sensor bolts to 89 inch lbs. (10 Nm).
  210.  
  211. Place the camshaft position actuator valves in position on the front cover.
  212.  
  213. Install the camshaft position actuator valve bolts. Tighten the camshaft position actuator valve bolts to 89 inch lbs. (10 Nm).
  214.  
  215. The EN 46106 must be installed onto the flywheel.
  216.  
  217. Use tool J 41998-B, nut, bearing and washer to install the crankshaft balancer.
    NOTE
    Do not lubricate the crankshaft front oil seal or crankshaft balancer sealing surfaces. The crankshaft balancer is installed into a dry seal.

  218.  
  219. Apply lubricant to the inside of the crankshaft balancer hub bore.
  220.  
  221. Place the crankshaft balancer in position on the crankshaft.
  222.  
  223. Thread tool J 41998-B in the crankshaft. Ensure you engage at least 10 threads of tool J 41998-B before pressing the crankshaft balancer in place.
  224.  
  225. Push the crankshaft balancer into position by tightening the nut on tool J 41998-B until the large washer bottoms out on the crankshaft end.
  226.  
  227. Remove tool J 41998-B.
  228.  
  229. Install the crankshaft balancer bolt.
  230.  
  231. Tighten the crankshaft balancer bolt. Tighten the crankshaft balancer bolt to 74 ft. lbs. (100 Nm).
  232.  
  233. Tighten the crankshaft balancer bolt an additional 150 degrees using tool J 45059.
  234.  
  235. Remove tool EN 46106.
  236.  
  237. The remainder of installation is the reverse of removal.
  238.  

 
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