CTS 2003-2005

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



2.8L & 3.6L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Do not disconnect the power steering lines.



    Negative battery cable
     
    Engine shroud
     
    Intake manifold
     
    Camshaft covers
     
    Purge vent hose from the water outlet
     
    Water outlet housing
     
    Accessory drive belts
     
    A/C compressor and power steering belt tensioner
     
    Alternator
     
    Alternator mounting bracket with belt tensioner
     



    Power steering fluid reservoir and reposition aside
     
    Power steering pump pulley
     
    Power steering pump upper front bolt and loosen two remaining bolts
     
    Crankshaft pulley
     
    Oil control valves
     
    Camshaft actuator valve bolts
     
    Camshaft actuator valves from the front cover
     
    Front cover mounting bolts
     

  8.  
  9. Loosely install a 10x1.5mm bolt in the jackscrew hole.
  10.  
  11. Using the pry points located on the edge of the front cover and the jackscrew, shear the RTV sealant.

    Click image to see an enlarged view

    Fig. Front cover pry locations-2.8L and 3.6L

  12.  
  13. Remove the front cover.
  14.  
  15. Remove or disconnect the following:

    Right bank secondary camshaft drive chain tensioner
     
    Right bank secondary camshaft drive chain shoe
     
    Right bank secondary camshaft drive chain guide
     
    Right bank secondary camshaft drive chain
     
    Primary camshaft drive chain tensioner
     
    Primary camshaft drive chain upper guide
     
    Primary camshaft drive chain timing chain
     

  16.  

To install:

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

    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)



    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).



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Make sure all primary drive chain timing marks all aligned-2.8L and 3.6L

  2.  
  3. Install the primary camshaft drive chain upper guide. Tighten the bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the primary camshaft drive chain tensioner as follows:
    1. Use the Special Tensioner Tool J-45027 to reset the primary camshaft drive chain tensioner plunger.

      Click image to see an enlarged view

      Fig. Reset the drive chain tensioner plunger with Special Tool J-45027.

    2.  
    3. Install the plunger into the tensioner body
    4.  
    5. Compress the plunger into the body and lock the tensioner by inserting the Special Retraction Tool EN-46112 into the access hole in the side of the tensioner body.

      Click image to see an enlarged view

      Fig. Lock the tensioner with Special Tool EN-46112-2.8L and 3.6L

    6.  
    7. Install a new gasket to the drive chain tensioner.
    8.  
    9. Place the primary camshaft drive chain tensioner into position and loosely install the bolts to the block.
    10.  
    11. Tighten the tensioner bolts to 44 inch lbs. (5 Nm) and then retighten to 17 ft. lbs. (23 Nm).
    12.  
    13. Release the tensioner by pulling out the Retraction Tool EN-46112.
    14.  

  6.  
  7. Install the right bank 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.



    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



    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).



    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).

  8.  
  9. Install the right secondary camshaft drive chain guide. Tighten the bolts to 17 ft. lbs. (23 Nm).
  10.  
  11. Install the right secondary camshaft drive chain shoe. Tighten the bolt to 17 ft. lbs. (23 Nm).
  12.  
  13. Install the right secondary camshaft drive chain tensioner as follows:
    1. Use the Special Tensioner Tool J-45027 to reset the primary camshaft drive chain tensioner plunger.
    2.  
    3. Install the plunger into the tensioner body
    4.  
    5. Compress the plunger into the body and lock the tensioner by inserting the Special Retraction Tool EN-46112 into the access hole in the side of the tensioner body.
    6.  
    7. Install a new gasket to the drive chain tensioner.
    8.  
    9. Place the primary camshaft drive chain tensioner into position and loosely install the bolts to the block.
    10.  
    11. Tighten the tensioner bolts to 44 inch lbs. (5 Nm) and then retighten to 17 ft. lbs. (23 Nm).
    12.  
    13. Release the tensioner by pulling out the Retraction Tool EN-46112.
    14.  

  14.  
  15. Install the 0.32 inch (8mm) guide pins into the cylinder block for the front cover.
  16.  
  17. Install a new front cover-to-cylinder block seal into the front cover.
  18.  
  19. Apply a 0.12 inch (3mm) bead of silicone sealant on the front cover as shown.

    Click image to see an enlarged view

    Fig. Front cover sealant locations-2.8L and 3.6L

  20.  
  21. Place the front cover into position on the engine block and remove the guide pins.
  22.  
  23. Hand start all of the engine front cover bolts.
  24.  
  25. Tighten the engine front cover bolts in sequence to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Front cover torque sequence-2.8L and 3.6L

  26.  
  27. Install or connect the following:

    Camshaft position sensors. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Camshaft position actuator valves. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Oil control valves
     
    Crankshaft pulley. Tighten the bolt to 74 ft. lbs. (100 Nm) plus 150 degrees.
     
    Power steering pump. Tighten the bracket bolts to 37 ft. lbs. (50 Nm).
     
    Power steering pump pulley
     
    Power steering fluid reservoir. Tighten the upper bolts to 80 inch lbs. (9 Nm) and lower bolt to 19 ft. lbs. (25 Nm).
     
    Alternator mounting bracket with belt tensioner. Tighten front bracket bolts to 37 ft. lbs. (50 Nm) and side bolt to 17 ft. lbs. (23 Nm).
     
    Alternator
     
    A/C compressor and power steering belt tensioner. Tighten the bolt to 37 ft. lbs. (50 Nm).
     
    Accessory drive belts
     
    Water outlet housing. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Purge vent hose to the water outlet housing
     
    Camshaft covers
     
    Intake manifold
     
    Engine shroud
     
    Negative battery cable
     

  28.  
  29. Fill the engine with oil to the correct level.
  30.  
  31. Fill the cooling system to the correct level.
  32.  
  33. Start the engine and check for leaks.
  34.  

5.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake system
     
    Radiator assembly
     
    A/C condenser
     
    A/C drive belt
     
    Starter motor
     
    Crankshaft pulley
     
    Water pump
     
    A/C belt tensioner
     
    Idler pulley
     
    Alternator and mounting bracket
     
    Oil pan-to-front cover bolts
     
    Front cover mounting bolts
     
    Front cover
     
    Oil pan
     
    Oil pump
     
    Camshaft sprocket bolts
     
    Camshaft sprocket
     
    Timing chain
     
    Timing chain guide
     

  8.  
  9. Install Crankshaft Sprocket Removal Tool J-41558, J-41816-2 and J-8433 onto the crankshaft sprocket.
  10.  
  11. Remove the crankshaft sprocket.

    Click image to see an enlarged view

    Fig. Removing the camshaft sprocket and timing chain-5.7L



    Click image to see an enlarged view

    Fig. Using the Crankshaft Sprocket Removal Tools-5.7L

  12.  

To install:

  1. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.
  2.  
  3. Using Special Tool J-41665, install the crankshaft sprocket. The crankshaft should be fully seated against the crankshaft flange.

    Click image to see an enlarged view

    Fig. Install the crankshaft sprocket using Special Tool J-41665-5.7L

  4.  
  5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o-clock position.
  6.  
  7. Install the timing chain guide. Tighten the guide bolts to 26 ft. lbs. (35 Nm).
  8.  
  9. Install the camshaft sprocket and timing chain. Align the camshaft sprocket locating pin with the camshaft sprocket alignment hole. Locate the camshaft sprocket alignment mark in the 6 o-clock position. Tighten the camshaft sprocket bolts to 26 ft. lbs. (35 Nm).

    Click image to see an enlarged view

    Fig. Timing chain alignment-5.7L

  10.  
  11. Install or connect the following:

    Oil pump
     
    Oil pan
     

  12.  
  13. Apply a 0.20 inch (5mm) bead of silicone sealant to the oil pan-to-engine block junction.
    NOTE
    Do apply any type of sealant directly to front cover gasket.

  14.  
  15. Install the front cover with a new gasket. Install the front cover bolts until snug.
  16.  
  17. Install the oil pan-to-front cover bolts until snug.
  18.  
  19. Align the tapered legs of Front Cover Alignment Tool J-41476 with the alignment surfaces on the front cover. Install the crankshaft pulley bolt through the alignment tool and tighten until snug.

    Click image to see an enlarged view

    Fig. Front cover alignment tool J-41476 installed-5.7L

  20.  
  21. Tighten the front cover mounting bolts to 18 ft. lbs. (25 Nm) and remove the Front Cover Alignment Tool.
  22.  
  23. Install or connect the following:

    Front crankshaft seal
     
    Alternator
     
    Idler pulley
     
    A/C belt tensioner
     
    Water pump
     
    Crankshaft pulley
     
    Starter motor
     
    A/C drive belt
     
    A/C condenser
     
    Radiator assembly
     
    Air intake system
     
    Negative battery cable
     

  24.  
  25. Refill the engine with oil to the correct level.
  26.  
  27. Refill the cooling system to the correct level.
  28.  
  29. Start the engine and check for leaks.
  30.  

 
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