BMW Cars 1999-06

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



M42 Engine
  1. Remove the ignition leads and valve cover. Remove the cam position sender on the upper cover. Drain the coolant and remove the thermostat housing. Remove the thermostat.
  2.  
  3. Remove the 11 bolts holding the upper timing cover. Remove the cover carefully to avoid damaging the head gasket.
  4.  
  5. Remove the radiator, fan, belts and water pump pulley. The water pump does not need to be removed to remove the lower cover.
  6.  
  7. Remove the damper and the crankshaft hub.
  8.  
  9. Remove the 21 bolts and remove the cover.
  10.  



Click image to see an enlarged view

Fig. Set the camshafts to TDC of cylinder no. 1-M42 engine



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Fig. Release the tensioner piston-M42 engine



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Fig. Compress the tensioner in a vice to reset it-M42 engine



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Fig. View of the mounting bolts for the upper chain guide-M42 engine



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Fig. Once the tensioner is installed, it must be released by pressing back on the tensioner rail-M42 engine

  1. Rotate the engine in the direction of the rotation until the camshaft peaks of the intake and exhaust camshafts for cylinder No. 1 face each other. The arrows on the sprocket face up.
  2.  
  3. Remove the chain tensioner. Remove the upper chain guide, chain guide bolt on the right side and the sprockets.
  4.  
  5. Remove the lower timing chain guide from under the crankshaft sprocket and lift out the timing chain.
  6.  

To install:

  1. Install Tool No. 11 2 300 or equivalent, to hold the crank at TDC. Install Tool No. 11 3 240 or equivalent, to hold the camshafts in proper alignment. If the camshafts have to be turned so much that the valves in cylinders 1 or 4 start to open, turn the crank 90 degrees in the direction of engine rotation. Turn the camshafts and install the tool, then rotate the crankshaft back to TDC. This will prevent the valves from striking the pistons.
  2.  
  3. Install the camshaft sprockets with the arrows pointing up. Torque to 10-12 ft. lbs. (13-17 Nm). Install the timing chain, timing guide bolt on the right side and the upper and lower chain guides.
  4.  
  5. If not installing a new tensioner piston, knock the outer sleeve of the tensioner piston so the piston is released from the sleeve. Assemble the tensioner with the spring, the piston and the snaprings in position. Place in a vice and press together until both snaprings engage. If the piston starts to extend, the procedure must be done again. The compressed tensioner will be 2.697 inch (68.5mm).
  6.  
  7. Install the tensioner into its bore and tighten the plug to 17-19 ft. lbs. (23-27 Nm). Push the tensioner rail against the tensioner to release the tensioner piston.
  8.  
  9. Check the engine block dowel sleeves. Install new gaskets on the cover. Check the condition of the radial seals and replace if necessary.
  10.  
  11. Install the cover and torque the M6 bolts to 6-7 ft. lbs. (8-10 Nm) and the M8 bolts to 15-17 ft. lbs. (20-24 Nm).
  12.  
  13. Install the crankshaft hub and damper. Install the water pump pulley and belts. Install the fan and radiator.
  14.  
  15. Place sealer at the head gasket to cover joints. Place the upper cover with new gaskets. Install 2 bolts and press the upper cover into place by wedging down against the camshaft sprocket. Torque the M6 bolts to 6-7 ft. lbs. (8-10 Nm) and the M8 bolts to 15-17 ft. lbs. (20-24 Nm).
  16.  
  17. Install the valve cover and ignition leads. Install the thermostat and cover. Install the cam position sender. Fill the cooling system with coolant mixture and bleed.
  18.  

M44 1.9L, M52 2.5L, 2.8L, And S52 3.2L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    The timing case cover can be removed without removing the water pump.


    NOTE
    The reversing roller can only be replaced complete with bearings.



    Negative battery cable
     
    Radiator and fan assembly
     
    Drive belts and any accessories that block access to the timing cover. Remove the engine splash shield.
     
    Vibration damper using a suitable tool, then remove the central bolt and remove the vibration damper hub
     
    Timing case cover bolts and timing cover
     



    Upper chain guide and top bolt on the right chain guide
     
    Timing chain sprockets and the lift out the chain. Remove the timing chain guide.
     
    Tensioning rail, if necessary. Remove the crankshaft sprocket with a suitable tool and lift out the Woodruff key.
     
    Reversing roller, if needed
     

  6.  

To install:

  1. Install the Woodruff key into the channel in the crankshaft. Slide the crankshaft sprocket over the end of the crankshaft with the Woodruff key aligning with the channel in the crankshaft. Use the central mounting bolt to draw the sprocket entirely into position.
  2.  
  3. Apply sealant at the intersections of the timing cover and the oil pan.
  4.  
  5. The remaining components are installed in the reverse order from which they were removed.
  6.  
  7. Tighten the remaining fasteners as follows:

    Camshaft sprocket bolts: 16 ft. lbs. (22 Nm)
     
    Timing cover M6 bolts: 78-96 inch lbs. (9-11 Nm)
     
    Timing cover M8 bolts: 16 ft. lbs. (22 Nm)
     
    Vibration damper central bolt: M44 engines: 243 ft. lbs. (330 Nm)
     
    Vibration damper central bolt: M52 and S52 engines: 302 ft. lbs. (410 Nm)
     
    Vibration damper pulley bolts: 17 ft. lbs. (23 Nm)
     

  8.  
  9. Connect the negative battery cable.
  10.  

M44, M52 And S52 Engines
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system and remove the radiator and fan assembly.
  4.  
  5. Remove the drive belts and any accessories that block access to the timing cover. Remove the engine splash shield.
  6.  
  7. Remove the vibration damper using a suitable tool, then remove the central bolt and remove the vibration damper hub.
  8.  
  9. Remove the timing case cover bolts and remove the timing cover.
  10.  


NOTE
The timing case cover can be removed without removing the water pump.

  1. Remove the upper chain guide and top bolt on the right chain guide.
  2.  
  3. Remove the timing chain sprockets and the lift out the chain. Remove the timing chain guide.
  4.  
  5. Remove the tensioning rail, if necessary. Remove the crankshaft sprocket with a suitable tool and lift out the Woodruff key.
  6.  
  7. Remove the reversing roller, if needed.
  8.  


NOTE
The reversing roller can only be replaced complete with bearings.

To install:

  1. Install the Woodruff key into the channel in the crankshaft. Slide the crankshaft sprocket over the end of the crankshaft with the Woodruff key aligning with the channel in the crankshaft. Use the central mounting bolt to draw the sprocket entirely into position.
  2.  
  3. Apply sealant at the intersections of the timing cover and the oil pan.
  4.  
  5. The remaining components are installed in the reverse order from which they were removed.
  6.  
  7. Tighten the remaining fasteners as follows:

    Camshaft sprocket bolts: 16 ft. lbs. (22 Nm)
     
    Timing cover M6 bolts: 78-96 inch lbs. (9-11 Nm)
     
    Timing cover M8 bolts: 16 ft. lbs. (22 Nm)
     
    Vibration damper central bolt: M44 engines: 243.4 ft. lbs. (330 Nm)
     
    Vibration damper central bolt: M52 and S52 engines: 302.4 ft. lbs. (410 Nm)
     
    Vibration damper pulley bolts: 17 ft. lbs. (23 Nm)
     

  8.  
  9. Connect the negative battery cable, start the engine and check for leaks.
  10.  

M50 And S50 Engines
  1. Remove the ignition coils and valve cover. Drain the coolant and remove the thermostat housing. Remove the thermostat.
  2.  
  3. Remove the 8 bolts holding the upper timing cover. Remove the cover carefully to avoid damaging the head gasket.
  4.  
  5. Remove the radiator, fan, belts and water pump pulley. The water pump does not need to be removed to remove the lower cover.
  6.  
  7. Remove the damper and the crankshaft hub.
  8.  
  9. Remove the 13 bolts and remove the cover.
  10.  



Click image to see an enlarged view

Fig. Inserting the clip to hold the tensioner in the released position-M50, S50, M52 and S52 engines



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Fig. Removing the camshaft sprockets-M50, S50, M52 and S52 engines



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Fig. Removing the upper chain tensioner-M50, S50, M52 and S52 engines

  1. Remove the upper timing case cover and the camshaft cover. Crank the engine in the direction of rotation so that the intake and exhaust camshaft peaks for cylinder No.1 face each other. Hold the camshafts in place with Tool No. 11 3 240 or equivalent. With the camshafts in this alignment the arrows on the sprockets will be facing up. Remove the valve cover mounting studs. Lock the flywheel in place to prevent movement of the crankshaft.
  2.  
  3. Unscrew the chain tensioner and carefully remove. There is a spring contained within the tensioner and may eject out if care is not taken.
  4.  
  5. Press down on the upper chain tensioner and lock it into place using Tool No. 11 3 290 or equivalent. Unscrew the transfer timing chain sprockets and pull the 2 off together with the chain. Remove the upper chain tensioner and the lower chain guide. Pull off the main timing chain sprocket along with the chain. Use a bent piece of wire to hold the chain from falling down into the engine. Do not rotate the engine after this point or the valve timing will be disturbed when the engine is reassembled.
  6.  
  7. Remove the lower timing chain cover and fold the tensioner rails down. Remove the timing chain.
  8.  

To install:

  1. Install the timing chain on the lower sprocket and on the upper sprocket.
  2.  
  3. Align main timing chain and sprocket on the camshaft so that the arrow faces up. The bolt holes in the camshaft should be on the left sides of the sprocket slots. This will allow the tensioner to take up the slack in the chain and rotate the gear to the counterclockwise position.
  4.  
  5. Install the upper chain tensioner and the lower chain guide. Install the transfer timing gears and chain on the camshafts with the arrows facing up. Make sure that the pulse sender is installed on the intake cam. Do not tighten the sprocket bolts.
  6.  
  7. Install the lower timing chain tensioner with the groove in a vertical position. Use a new sealing ring and torque to 29 ft. lbs. (40 Nm).
  8.  
  9. Release the upper timing chain tensioner and torque the sprocket bolts to 16 ft. lbs. (22 Nm).
  10.  
  11. Check the engine block dowel sleeves. Install new gaskets on the cover. Check the condition of the radial seals and replace if necessary.
  12.  
  13. Install the lower timing cover and accessories. Install the upper timing cover. Tighten the retainers as follows:

    M6 bolts to 6-7 ft. lbs. (8-10 Nm)
     
    M8 bolts to 15-17 ft. lbs. (20-24 Nm)
     

  14.  
  15. Install the crankshaft hub and damper. Install the water pump pulley and belts. Install the fan and radiator.
  16.  
  17. Place the upper cover with new gaskets. Torque the M6 bolts to 6-7 ft. lbs. (8-10 Nm) and the M8 bolts to 15-17 ft. lbs. (20-24 Nm).
  18.  
  19. Install the valve cover mounting studs and remove the flywheel lock. Install the camshaft cover and the timing case covers using new gaskets. Install the lifting eye and the electrical lead duct. Install the camshaft sensor with a new seal if needed.
  20.  
  21. Install the valve cover using new gaskets if necessary. Check that the gasket seats correctly all the way around the seating area.
  22.  
  23. Install the ignition coils and connect the electrical leads to each coil.
  24.  
  25. Install the thermostat with the arrow or vent facing up with a new O-ring. Install the thermostat housing with a new gasket. Install the intake manifold and throttle valve. Install the exhaust manifolds. Change the oil and check all fluid levels.
  26.  

M54 And S54 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator and fan assembly
     
    Drive belts and any accessories that block access to the timing cover
     
    Engine splash shield
     
    Vibration damper using a suitable tool, then remove the central bolt and remove the vibration damper hub
     
    Timing case cover bolts and timing cover
     

  6.  


NOTE
The timing case cover can be removed without removing the water pump.



Upper chain guide and top bolt on the right chain guide
 
Timing chain sprockets and the lift out the chain
 
Timing chain guide
 
Tensioning rail, if necessary.
 
Crankshaft sprocket with a suitable tool and lift out the Woodruff key
 
Reversing roller, if needed
 


NOTE
The reversing roller can only be replaced complete with bearings.

To install:

  1. Install the Woodruff key into the channel in the crankshaft. Slide the crankshaft sprocket over the end of the crankshaft with the Woodruff key aligning with the channel in the crankshaft. Use the central mounting bolt to draw the sprocket entirely into position.
  2.  
  3. Apply sealant at the intersections of the timing cover and the oil pan.
  4.  
  5. The remaining components are installed in the reverse order from which they were removed.
  6.  
  7. Tighten the remaining fasteners as follows:

    Camshaft sprocket bolts: 16 ft. lbs. (22 Nm)
     
    Timing cover M6 bolts: 78-96 inch lbs. (9-11 Nm)
     
    Timing cover M8 bolts: 16 ft. lbs. (22 Nm)
     
    Vibration damper central bolt: M44 engines: 243 ft. lbs. (330 Nm)
     
    Vibration damper central bolt: M52 and S52 engines: 302 ft. lbs. (410 Nm)
     
    Vibration damper pulley bolts: 17 ft. lbs. (23 Nm)
     

  8.  
  9. Connect the negative battery cable.
  10.  

M62 Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    front engine splash shield
     
    Left cylinder head cover
     
    Alternator
     
    Oil filter housing
     
    Left upper timing cover
     
    Right cylinder head cover
     
    Mass Air Flow (MAF) sensor
     
    Timing chain tensioner and mount
     
    Camshaft Position (CMP) sensor
     
    Oil dipstick tube
     
    Right timing cover
     
    Engine cooling fan
     
    Water pump pulley
     
    Crankshaft damper pulley and hub
     
    Front crankshaft seal using tool No. 11-2-380 and 11-2-383
     
    Lower timing cover
     

  4.  
  5. Turn the engine in the direction of rotation and set cylinder number 1 to TDC firing. The arrows on the sprockets should face up in the cylinder axis. Use a crankshaft holder to keep the TDC position.
  6.  
  7. Loosen and remove the camshaft sprocket bolts from both banks of cylinders. Compress the hydraulic tensioning element to loosen the timing chain. Lock the element with tool No. 11-3-420, or equivalent and remove the sprockets with the chain. Do not rotate the engine with the timing chain removed.
  8.  
  9. Guide the chain out of the tensioner rails and off the lower sprocket.
  10.  
  11. To remove the guide rail:
    1. On the left side (cylinder bank 1-4), remove the lower mounting bolt and remove the tensioning rail. Remove the spacer for the tensioning rail.
    2.  
    3. On the left side, remove the 2 mounting bolts for the guide rail. Do not mix the 2 bolts, it is important to install the same bolt in the same hole. Remove the sliding rail.
    4.  
    5. On the right side (cylinder bank 5-8), remove the 2 mounting bolts on the tensioning rail, and the 2 bolts on the guide rail. Remove the rails.
    6.  

  12.  

To install:

  1. On the right cylinder bank, position the guide rail and install the mounting bolts. Position the tensioning rail, and install the mounting bolts.
  2.  
  3. On the left cylinder bank, check the seal for the spacer. Position the guide rail, and install the mounting bolts in the correct holes. Install the spacer. Position the tensioning rail, and install the lower mounting bolt.
  4.  
  5. Inspect the sprockets for wear and replace if necessary.
  6.  
  7. Install the chain in position.
  8.  
  9. Be sure No. 1 piston remains at the TDC on the firing stroke and the key on the crankshaft is in the 12 o'clock position.
  10.  
  11. Position the chain on the guide rail and swing the chain inward and to the left.
  12.  
  13. Engage the chain on the crankshaft gear and install the camshaft sprockets into the chain.
  14.  
  15. The sprocket, on the intake camshaft for cylinder bank 1-4, has a sender pin. With the arrow pointing up, align the pin in the middle of the slots, then install the camshaft sprockets. Remove tool No. 11-3-420 and remove the crankshaft holder.
  16.  
  17. Install the chain tensioner piston, spring and cap plug, but do not tighten.
  18.  
  19. To bleed the chain tensioner, fill the oil pocket located on the upper timing housing cover with engine oil and move the tensioner back and forth with a suitable prytool until oil is expelled at the cap plug, then tighten the cap plug securely.
  20.  
  21. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces thoroughly, then place a new gasket on the lower cover.
  22.  
  23. Trim the protruding ends of the gasket, making sure the cutting tool is level. Do not allow the pieces to fall into the engine.
  24.  
  25. Position the lower cover and install the mounting bolts with an even distribution of pressure. Tighten the 6mm bolts to 84 inch lbs. (10 Nm), 8mm bolts to 16 ft. lbs. (22 Nm) and 10mm bolts to 35 ft. lbs. (47 Nm)
  26.  
  27. Install the oil seal in the timing case cover using tool No. 11 1 220 or an equivalent seal driver. Make sure the seal is flush with the cover.
  28.  
  29. Install the vibration damper hub and install the mounting bolt. Tighten the hub bolt as follows:
    1. Step 1: 74 ft. lbs. (100 Nm).
    2.  
    3. Step 2: Plus 60 degrees.
    4.  
    5. Step 3: Plus 60 degrees.
    6.  
    7. Step 4: Plus 30 degrees.
    8.  

  30.  
  31. Raise and safely support the vehicle. Install the cooling air guide for the alternator, located on the engine carrier. Install the front engine splash shield and lower the vehicle.
  32.  
  33. Position the vibration damper pulleys and install the mounting bolts for the damper.
  34.  
  35. Install the pulley on the water pump.
  36.  
  37. Install the drive belt and the cooling fan. Rotate the fan counterclockwise to install.
  38.  
  39. Install the intake hose between the throttle body and the air volume meter, then install the manifold cover.
  40.  
  41. Replace the hydraulic tensioner oil seal in the timing case cover.
  42.  
  43. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces to remove any oil or old gasket material and install a new gasket.
  44.  
  45. Mount the timing case cover. Screw in the vertically mounted bolts until the cover contacts the cylinder head. Do not fully tighten the bolts.
  46.  
  47. Install the horizontally mounted bolts, then tighten the vertically mounted bolts in 2 steps. After the vertically mounted bolts have been tightened, torque the horizontally mounted bolts in 2 steps to a final torque as follows:

    M6 bolts: 84 inch lbs. (10 Nm)
     
    M8 bolts: 16 ft. lbs. (22 Nm)
     
    M10 bolts: 35 ft. lbs. (47 Nm)
     

  48.  
  49. Install the oil dipstick guide tube, making sure to replace and lubricate the O-ring.
  50.  
  51. Install the camshaft sender fastener and the chain tensioner.
  52.  
  53. Install the air cleaner upper section along with the MAF sensor.
  54.  
  55. Install the right cylinder head cover.
  56.  
  57. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces to remove any oil or old gasket material and install a new gasket.
  58.  
  59. Mount the timing case cover together with the inserted bolt. This bolt cannot be installed with the cover in place. Install the rest of the mounting bolts and fasten the vertically mounted bolts until the cover just contacts the cylinder head. Do not fully tighten the bolts.
  60.  
  61. Install the horizontally mounted bolts, then tighten the vertically mounted bolts in 2 steps. After the vertically mounted bolts have been tightened, torque the horizontally mounted bolts in 2 steps to a final torque as follows: M6 bolts: 84 inch lbs. (10 Nm), M8 bolts: 16 ft. lbs. (22 Nm), M10 bolts: 35 ft. lbs. (47 Nm)
  62.  
  63. Install or connect the following:

    Battery positive cable for the alternator and install the protective tube mounting fasteners and connect the remaining wires to the alternator
     
    Oil filter housing and the return pipe and replace the housing cover
     
    Alternator and cylinder head cover
     
    Negative battery cable
     

  64.  


    Click image to see an enlarged view

    Fig. The timing chain tensioner slides out of the side of the front cover-M62 engines



    Click image to see an enlarged view

    Fig. Camshaft sprocket sender pin-M62 engines


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt
     
    front engine splash shield
     
    Left cylinder head cover
     
    Alternator
     
    Oil filter housing
     
    Left upper timing cover
     
    Right cylinder head cover
     
    Mass Air Flow (MAF) sensor
     
    Timing chain tensioner and mount
     
    Camshaft Position (CMP) sensor
     
    Oil dipstick tube
     
    Right timing cover
     
    Engine cooling fan
     
    Water pump pulley
     
    Crankshaft damper pulley and hub
     
    Front crankshaft seal using tool No. 11-2-380 and 11-2-383
     
    Lower timing cover
     

  4.  
  5. Turn the engine in the direction of rotation and set cylinder number 1 to TDC firing. The arrows on the sprockets should face up in the cylinder axis. Use a crankshaft holder to keep the TDC position.
  6.  
  7. Loosen and remove the camshaft sprocket bolts from both banks of cylinders. Compress the hydraulic tensioning element to loosen the timing chain. Lock the element with tool No. 11-3-420, or equivalent and remove the sprockets with the chain. Do not rotate the engine with the timing chain removed.
  8.  
  9. Guide the chain out of the tensioner rails and off the lower sprocket.
  10.  
  11. To remove the guide rail:
    1. On the left side (cylinder bank 1-4), remove the lower mounting bolt and remove the tensioning rail. Remove the spacer for the tensioning rail.
    2.  
    3. On the left side, remove the 2 mounting bolts for the guide rail. Do not mix the 2 bolts, it is important to install the same bolt in the same hole. Remove the sliding rail.
    4.  
    5. On the right side (cylinder bank 5-8), remove the 2 mounting bolts on the tensioning rail, and the 2 bolts on the guide rail. Remove the rails.
    6.  

  12.  

To install:

  1. On the right cylinder bank, position the guide rail and install the mounting bolts. Position the tensioning rail, and install the mounting bolts.
  2.  
  3. On the left cylinder bank, check the seal for the spacer. Position the guide rail, and install the mounting bolts in the correct holes. Install the spacer. Position the tensioning rail, and install the lower mounting bolt.
  4.  
  5. Inspect the sprockets for wear and replace if necessary.
  6.  
  7. Install the chain in position.
  8.  
  9. Be sure No. 1 piston remains at the TDC on the firing stroke and the key on the crankshaft is in the 12 o'clock position.
  10.  
  11. Position the chain on the guide rail and swing the chain inward and to the left.
  12.  
  13. Engage the chain on the crankshaft gear and install the camshaft sprockets into the chain.
  14.  
  15. The sprocket, on the intake camshaft for cylinder bank 1-4, has a sender pin. With the arrow pointing up, align the pin in the middle of the slots, then install the camshaft sprockets. Remove tool No. 11-3-420 and remove the crankshaft holder.
  16.  
  17. Install the chain tensioner piston, spring and cap plug, but do not tighten.
  18.  
  19. To bleed the chain tensioner, fill the oil pocket located on the upper timing housing cover with engine oil and move the tensioner back and forth with a suitable prytool until oil is expelled at the cap plug, then tighten the cap plug securely.
  20.  
  21. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces thoroughly, then place a new gasket on the lower cover.
  22.  
  23. Trim the protruding ends of the gasket, making sure the cutting tool is level. Do not allow the pieces to fall into the engine.
  24.  
  25. Position the lower cover and install the mounting bolts with an even distribution of pressure. Tighten the 6mm bolts to 84 inch lbs. (10 Nm), 8mm bolts to 16 ft. lbs. (22 Nm) and 10mm bolts to 35 ft. lbs. (47 Nm)
  26.  
  27. Install the oil seal in the timing case cover using tool No. 11 1 220 or an equivalent seal driver. Make sure the seal is flush with the cover.
  28.  
  29. Install the vibration damper hub and install the mounting bolt. Tighten the hub bolt as follows:

    Step 1: 74 ft. lbs. (100 Nm)
     
    Step 2: Plus 60 degrees
     
    Step 3: Plus 60 degrees
     
    Step 4: Plus 30 degrees
     

  30.  
  31. Raise and safely support the vehicle. Install the cooling air guide for the alternator, located on the engine carrier. Install the front engine splash shield and lower the vehicle.
  32.  
  33. Position the vibration damper pulleys and install the mounting bolts for the damper.
  34.  
  35. Install the pulley on the water pump.
  36.  
  37. Install the drive belt and the cooling fan. Rotate the fan counterclockwise to install.
  38.  
  39. Install the intake hose between the throttle body and the air volume meter, then install the manifold cover.
  40.  
  41. Replace the hydraulic tensioner oil seal in the timing case cover.
  42.  
  43. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces to remove any oil or old gasket material and install a new gasket.
  44.  
  45. Mount the timing case cover. Screw in the vertically mounted bolts until the cover contacts the cylinder head. Do not fully tighten the bolts.
  46.  
  47. Install the horizontally mounted bolts, then tighten the vertically mounted bolts in 2 steps. After the vertically mounted bolts have been tightened, torque the horizontally mounted bolts in 2 steps to a final torque as follows:

    M6 bolts: 84 inch lbs. (10 Nm)
     
    M8 bolts: 16 ft. lbs. (22 Nm)
     
    M10 bolts: 35 ft. lbs. (47 Nm)
     

  48.  
  49. Install the oil dipstick guide tube, making sure to replace and lubricate the O-ring.
  50.  
  51. Install the camshaft sender fastener and the chain tensioner.
  52.  
  53. Install the air cleaner upper section along with the MAF sensor.
  54.  
  55. Install the right cylinder head cover.
  56.  
  57. Check for the correct seating of the dowel sleeves. Clean the sealing surfaces to remove any oil or old gasket material and install a new gasket.
  58.  
  59. Mount the timing case cover together with the inserted bolt. This bolt cannot be installed with the cover in place. Install the rest of the mounting bolts and fasten the vertically mounted bolts until the cover just contacts the cylinder head. Do not fully tighten the bolts.
  60.  
  61. Install the horizontally mounted bolts, then tighten the vertically mounted bolts in 2 steps. After the vertically mounted bolts have been tightened, torque the horizontally mounted bolts in 2 steps to a final torque as follows: M6 bolts: 84 inch lbs. (10 Nm), M8 bolts: 16 ft. lbs. (22 Nm), M10 bolts: 35 ft. lbs. (47 Nm)
  62.  
  63. Install or connect the following:

    Battery positive cable for the alternator and install the protective tube mounting fasteners and connect the remaining wires to the alternator
     
    Oil filter housing and the return pipe and replace the housing cover
     
    Alternator and cylinder head cover
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. The timing chain tensioner slides out of the side of the front cover-M62 4.4L engines



    Click image to see an enlarged view

    Fig. Camshaft sprocket sender pin-M62 4.4L engines

     

  64.  

M73 5.4L Engines


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Fig. With the timing case cover fitted correctly, the retaining tab is not visible-M73 5.4L engines



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Fig. Timing chain tensioner components-M73 5.4L engines



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Fig. Timing chain tensioner adjustment: dimension "B" from "A" should be 0.216-0.256 inches (5.48-6.5mm)-M73 5.4L engines

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Fan assembly by rotating it clockwise
     
    Drive belts and engine splash shield. Remove the tensioning bolt.
     
    Both intake manifolds and distributor housings
     
    Round rubber mounts, bolts and nuts. Remove both cylinder head covers.
     
    Mounting bolts and lift out the timing cover
     
    Bolts but do not remove the vibration damper. Remove the central hub bolt with a suitable tool.
     
    Vibration damper using a suitable tool to pull the vibration damper hub from the crankshaft
     
    Engine oil, and then the lower section of the oil pan
     
    Bottom mounting fasteners from the timing case cover and loosen the adjacent oil pan bolts on both sides
     
    Timing chain tensioner and reference mark sender
     
    Timing case mounting fasteners and remove the timing case cover
     
    Front cover oil seal using tool No. 11-1-210
     

  4.  
  5. Set the engine to TDC firing for cylinder number one. Install suitable holder to secure the crankshaft in this position. The valves of No. 1 and No. 7 cylinders should be closed with the crankshaft in this position. The dowel pins in the camshafts should be facing in.
  6.  
  7. Remove or disconnect the following:

    Mounting bolts on the camshaft sprockets and carefully remove the sprockets with the timing chain
     
    Mounting bolts for the timing chain guide and remove the guide
     

  8.  

To install:

  1. Position and install the timing chain guide.
  2.  
  3. Position the timing chain on the sprockets and install the camshaft sprockets. Verify that the timing chain is correctly aligned on all the sprockets, then remove the crankshaft holder.
  4.  
  5. Lubricate the sealing lip of the shaft seal with oil and install the new seal using a suitable seal installer. The seal should be flush with the cover when installed.
  6.  
  7. Install or connect the following:

    Timing chain cover and mounting bolts
     
    Reference mark sender and the timing chain tensioner
     
    Remaining components in the reverse order of removal
     

  8.  
  9. Torque the central vibration damper hub bolt as follows:

    Step 1: 74 ft. lbs. (100 Nm)
     
    Step 2: turn an additional 60 degrees
     
    Step 3: turn an additional 60 degrees
     

  10.  
  11. Tighten the vibration damper pulleys to 17 ft. lbs. (25 Nm).
  12.  
  13. Install or connect the following:

    Both cylinder head covers
     
    The remaining components in the reverse order from which they were removed
     
    Engine splash shield
     
    Fan assembly
     
    Negative battery cable
     

  14.  
  15. Fill the engine with clean oil.
  16.  
  17. Fill and bleed the cooling system.

    Click image to see an enlarged view

    Fig. Camshaft dowel pins with the engine at TDC-M73 5.4L engines

  18.  

S14 Engine
  1. Disconnect the negative battery cable. Drain the cooling system through the bottom of the radiator. Remove the radiator and fan.
  2.  
  3. Disconnect all electrical plugs, remove the attaching nuts, and remove the air cleaner and airflow sensor.
  4.  
  5. Note and, if necessary, mark the wiring connections. Then, disconnect all alternator wiring. Unbolt the alternator and remove it and the drive belt.
  6.  
  7. Unbolt the power steering pump. Remove the belt and then move the pump aside, supporting it out of the way but in a position where the hoses will not be stressed.
  8.  
  9. Remove the 3 bolts from the bottom of the bell housing and the 2 bolts below it which fasten the reinforcement plate in place.
  10.  
  11. Remove the drain plug and drain the oil from the lower oil pan. Then, remove the lower oil pan bolts and remove the lower pan.
  12.  
  13. Remove the 3 bolts fastening the bottom of the front cover to the front of the oil pan. Loosen all the remaining oil pan bolts so the pan may be shifted downward just slightly to separate the gasket surfaces.
  14.  
  15. Remove the water pump. Remove the center bolt and use a puller to remove the crankshaft pulley.
  16.  
  17. Remove the piston for the timing chain tensioner.
  18.  
  19. Remove the bolts attaching the top of the front cover to the cylinder head. Then, remove all the bolts fastening the cover to the block.
  20.  
  21. Run a sharp bladed tool carefully between the upper surface of the oil pan gasket and the lower surface of the front cover to separate them without tearing the gasket. If the gasket is damaged, remove the oil pan and replace it.
  22.  
  23. If necessary, remove the distributor cap, rotor and rotor adapter. Remove the distributor housing and the intake camshaft end cover.
  24.  
  25. Remove the socket head bolts holding the upper timing chain guide. Turn the engine in the direction of rotation to TDC of cylinder number 1. Do not move the position of the engine from this point on.
  26.  
  27. Remove the timing tensioner piston. There is strong spring pressure behind the plug.
  28.  
  29. Unfold the sprocket bolt lock plate and remove the sprocket bolts. Remove the sprockets.
  30.  
  31. Remove the 2 snaprings for the guide rail, which is located on the left (driver's) side of the engine.
  32.  
  33. Pull the guide rail forward and then turn it up to free it from the chain.
  34.  

To install:

  1. Install the timing chain and the guide rail. Install the guide rail snaprings. Place the chain around the lower sprocket
  2.  
  3. Engage the chain with the intake side (E) sprocket with the marks aligned. Turn the intake side (E) sprocket in the direction opposite to normal rotation to tension the timing chain on that side. Bolt this sprocket and the lock plates onto the front end of the intake camshaft. Prevent the camshaft from rotating and torque the bolts to 6-7 ft. lbs. (8-10 Nm). Fold the lock plates up.
  4.  
  5. Engage the timing marks with the mark on the exhaust side (A) sprocket and install the sprocket and lock plates onto the front end of the exhaust camshaft. Use the distributor rotor adapter to keep the sprocket from turning, and torque the bolts to 6-7 ft. lbs. (8-10 Nm). Fold the lock plates up. Make sure the timing chain has stayed in time.
  6.  
  7. Slide the chain tensioner piston into its cylinder. Install a new seal. Now install the spring with the conical end out. Install the cap which retains the spring. Add oil to the well where the piston contacts the tensioner rail. Loosen the nipple on the plug and keep adding oil until oil runs out of the nipple. Close the nipple and torque the cap to 29 ft. lbs. (40 Nm).
  8.  
  9. Turn the engine 1 revolution in the normal direction of rotation. Recheck the timing. With the crankshaft at TDC, one groove on each camshaft faces inward and another on each faces the cast boss on the bearing cap.
  10.  
  11. Install the upper timing chain guide. Check and adjust the guide so the chain is centered in the guide.
  12.  
  13. Before reinstalling the cover, use a file to break or file off flashing at the top/rear of the casting on either side so the corner is smooth. Replace all gaskets, coating them with silicone sealer. Where gasket ends extend too far, trim them off. Apply sealer to the area where the oil pan gasket passes the front of the block.
  14.  
  15. Slide the cover straight on to avoid damaging the seal. Install all bolts in their proper positions. Coat the 3 bolts fastening the front cover to the upper oil pan with the proper sealant.
  16.  
  17. Tighten the bolts at the top, fastening the lower cover to the upper cover first. Then, tighten the remaining front cover bolts and, finally, the oil pan bolts to 7 ft. lbs. (9 Nm). Torque the M6 bolts to 6-7 ft. lbs. (8-10 Nm) and the M8 bolts to 15-17 ft. lbs. (20-24 Nm). Inspect the sealing O-rings and replace, as necessary. If it uses the DME distributor with the screw-off type rotor, make sure the bolt at the center of the rotor has its seal in place and that it is installed with a sealer designed to prevent the bolt from backing out.
  18.  
  19. Torque the oil drain plug to 24 ft. lbs. (32 Nm) and both upper and lower oil pan bolts to 7 ft. lbs. (10 Nm).
  20.  
  21. Reverse the remaining portions of the removal procedures, making sure to fill and bleed the cooling system and to refill the oil pan with the correct oil.
  22.  

 
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