Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo, Regal 2001-2005

Timing Chain Cover, Chain, Sprockets, & Seal 1

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Removal & Installation



3.1L & 3.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Coolant reservoir
     
    Accessory drive belt
     
    Crankshaft balancer
     
    Drive belt tensioner
     
    Power steering pump, DO NOT disconnect the lines
     
    Thermostat bypass pipe from the front cover
     
    Upper radiator hose
     
    Water pump pulley
     
    Lower Crankshaft Position (CKP) sensor
     
    Front cover
     

  8.  
  9. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment (facing each other).

    Camshaft sprocket bolt, sprocket and timing chain
     
    Crankshaft sprocket
     
    Timing chain damper bolts and damper, if necessary

    Click image to see an enlarged view

    Fig. Be sure to align the damper mark (1) with the crankshaft mark (2) and the damper mark (3) with the camshaft sprocket mark (4)-3.1L and 3.4L engines

     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.



    Timing chain damper (if removed) and torque the bolts to 15 ft. lbs. (21 Nm)
     
    Crankshaft sprocket
     



    Timing chain over the camshaft sprocket
     

  2.  
  3. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft.
  4.  
  5. Verify that the marks are aligned; the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position.
    NOTE
    The No. 1 piston will be at Top Dead Center (TDC) and the No. 4 piston will also be at TDC but on the compression stroke.

  6.  
  7. Tighten the camshaft sprocket bolt to 103 ft. lbs. (140 Nm).
  8.  
  9. Lubricate the timing chain components with engine oil.
  10.  
  11. Install or connect the following:

    New front cover seal
     
    Front cover using a new gasket and torque the small bolts to 20 ft. lbs. (27 Nm) and the large bolts to 41 ft. lbs. (55 Nm)
     
    Water pump pulley and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Upper radiator hose
     
    Thermostat bypass pipe
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Drive belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
     
    CKP sensor
     
    Crankshaft balancer and torque the bolt to 76 ft. lbs. (103 Nm)
     
    Accessory drive belt
     
    Coolant reservoir
     
    Negative battery cable
     

  12.  
  13. Refill the fluids.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Coolant reservoir
     
    Accessory drive belt
     
    Crankshaft balancer
     
    Drive belt tensioner
     
    Power steering pump, DO NOT disconnect the lines
     
    Thermostat bypass pipe from the front cover
     
    Upper radiator hose
     
    Water pump pulley
     
    Lower Crankshaft Position (CKP) sensor
     
    Front cover
     

  8.  
  9. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment (facing each other).

    Camshaft sprocket bolt, sprocket and timing chain
     
    Crankshaft sprocket
     
    Timing chain damper bolts and damper, if necessary

    Click image to see an enlarged view

    Fig. Be sure to align the damper mark (1) with the crankshaft mark (2) and the damper mark (3) with the camshaft sprocket mark (4)-3.1L and 3.4L engines

     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.



    Timing chain damper (if removed) and torque the bolts to 15 ft. lbs. (21 Nm)
     
    Crankshaft sprocket
     



    Timing chain over the camshaft sprocket
     

  2.  
  3. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft.
  4.  
  5. Verify that the marks are aligned; the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position.
    NOTE
    The No. 1 piston will be at Top Dead Center (TDC) and the No. 4 piston will also be at TDC but on the compression stroke.

  6.  
  7. Tighten the camshaft sprocket bolt to 103 ft. lbs. (140 Nm).
  8.  
  9. Lubricate the timing chain components with engine oil.
  10.  
  11. Install or connect the following:

    New front cover seal
     
    Front cover using a new gasket and torque the small bolts to 15 ft. lbs. (21 Nm) and the large bolts to 35 ft. lbs. (47 Nm)
     
    Water pump pulley and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Upper radiator hose
     
    Thermostat bypass pipe
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Drive belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
     
    CKP sensor
     
    Crankshaft balancer and torque the bolt to 76 ft. lbs. (103 Nm)
     
    Accessory drive belt
     
    Coolant reservoir
     
    Negative battery cable
     

  12.  
  13. Refill the fluids.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  

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

    Negative battery cable
     
    Coolant reservoir
     
    Accessory drive belt
     
    Crankshaft balancer
     
    Drive belt tensioner
     
    Power steering pump, DO NOT disconnect the lines
     
    Thermostat bypass pipe from the front cover
     
    Upper radiator hose
     
    Water pump pulley
     
    Lower Crankshaft Position (CKP) sensor
     
    Front cover
     

  8.  
  9. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment (facing each other).

    Camshaft sprocket bolt, sprocket and timing chain
     
    Crankshaft sprocket
     
    Timing chain damper bolts and damper, if necessary

    Click image to see an enlarged view

    Fig. Be sure to align the damper mark (1) with the crankshaft mark (2) and the damper mark (3) with the camshaft sprocket mark (4)-3.4L engines

     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.



    Timing chain damper (if removed) and torque the bolts to 15 ft. lbs. (21 Nm)
     
    Crankshaft sprocket
     



    Timing chain over the camshaft sprocket
     

  2.  
  3. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft.
  4.  
  5. Verify that the marks are aligned; the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position.
    NOTE
    The No. 1 piston will be at Top Dead Center (TDC) and the No. 4 piston will also be at TDC but on the compression stroke.

  6.  
  7. Tighten the camshaft sprocket bolt to 103 ft. lbs. (140 Nm).
  8.  
  9. Lubricate the timing chain components with engine oil.
  10.  
  11. Install or connect the following:

    New front cover seal
     
    Front cover using a new gasket and torque the small bolts to 20 ft. lbs. (27 Nm) and the large bolts to 41 ft. lbs. (55 Nm)
     
    Water pump pulley and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Upper radiator hose
     
    Thermostat bypass pipe
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Drive belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
     
    CKP sensor
     
    Crankshaft balancer and torque the bolt to 76 ft. lbs. (103 Nm)
     
    Accessory drive belt
     
    Coolant reservoir
     
    Negative battery cable
     

  12.  
  13. Refill the fluids.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  

3.5L & 3.9L Engines
Primary Chain
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the camshaft covers.
  10.  
  11. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the flats on the rear of the camshafts are parallel with the camshaft cover sealing surface.
  12.  
  13. Install camshaft holding fixtures on both sets of camshafts. Turn the hex portion of the camshaft to align them for tool installation.
    NOTE
    When installed, the flats on the rear of the camshafts will be parallel with the camshaft cover sealing surface.

  14.  
  15. Remove or disconnect the following:

    Right diagonal brace
     
    Battery and tray
     
    Coolant reservoir
     
    Underhood accessory wiring junction block, move it aside
     
    Drive belt
     
    Power steering pump pulley
     
    Idler pulley and belt tensioner
     
    Water pump pulley
     
    Water pump drive belt shield
     
    Water pump
     

  16.  
  17. Support the engine cradle.
  18.  
  19. Remove the right side engine cradle bolts.
  20.  
  21. Lower the cradle.
  22.  
  23. Remove or disconnect the following:
    NOTE
    Note that each plug has an O-ring.


    NOTE
    Remove the lower bolt allowing the tensioner to swing down and expand.



    Crankshaft balancer
     
    Front cover
     
    Engine lift bracket from the front of the engine
     
    Camshaft Position (CMP) sensor
     
    Sprocket bolt from the exhaust camshaft on the right cylinder head to allow for clearance of the chain guide
     
    Four chain guide access plugs from the cylinder heads
     



    Primary chain tensioner
     



    Primary chain tensioner shoe, by removing the bolt, pushing the guide downward slightly and pulling it up through the cylinder head
     
    Primary chain from the right camshaft, allowing it to fall into the oil pump area
     
    Primary chain

    Click image to see an enlarged view

    Fig. Primary timing chain alignment marks-3.5L engine



    Click image to see an enlarged view

    Fig. Compressing the primary chain tensioner-3.5L engine



    Click image to see an enlarged view

    Fig. Apply RTV sealant to the 3 areas indicated before installing the front cover and gasket-3.5L engine

     

  24.  

To install:

  1. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the mark on the crankshaft is at the 4 o-clock position.
  2.  
  3. Rotate the balance shaft so the timing mark is at the 5 o-clock position.
    NOTE
    Be sure the painted links are facing the front of the engine.

  4.  
  5. Install the timing chain on the sprockets.
  6.  
  7. Center the mark on the left intake camshaft sprocket between the 2 painted links.
  8.  
  9. Verify that all of the timing marks are aligned.
  10.  
  11. Install the primary chain tensioner shoe. Torque the bolt to 22 ft. lbs. (30 Nm).
  12.  
  13. Compress the primary chain tensioner using the following sub-steps:
    1. Step 1: Rotate the ratchet release lever counterclockwise and hold it.
    2.  
    3. Step 2: Press the tensioner shoe in and hold it.
    4.  
    5. Step 3: Release the ratchet lever and slowly release the pressure on the shoe.
    6.  
    7. Step 4: Insert a pin through the hole in the lever as the lever moves to the first click. The ratchet should hold the shoe in the compressed position.
      NOTE
      Be sure the lever on the tensioner is facing you when installed.

    8.  

  14.  
  15. Install or connect the following:

    Primary chain tensioner and torque the bolts to 18 ft. lbs. (25 Nm); then, remove the chain tensioner pin
     
    Four chain guide access plugs and torque the plugs to 44 inch lbs. (5 Nm)
     
    Front engine lift bracket and torque the hex head bolt to 37 ft. lbs. (50 Nm) and the internal drive bolt to 18 ft. lbs. (25 Nm)
     
    CMP sensor and torque the bolts to 80 inch lbs. (9 Nm)
     

  16.  
  17. Remove the camshaft holding tools.
  18.  
  19. Install the rocker arm covers. Torque the bolts to 80 inch lbs. (9 Nm).
  20.  
  21. Place a small bead of RTV sealant on the 3 areas indicated in the diagram.
  22.  
  23. Install or connect the following:

    Front cover with a new gasket and torque the bolts to 124 inch lbs. (14 Nm) and the coolant drain plug to 89 inch lbs. (10 Nm)
     
    Crankshaft balancer and torque the bolt to 37 ft. lbs. (50 Nm) plus an additional 120 degree turn
     

  24.  
  25. Raise the engine cradle and install new bolts loosely.
  26.  
  27. Coat the sub-frame bushings with rubber lubricant.
  28.  
  29. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, 3 / 4 inches thick by 8 inches long through the alignment holes on the right side of the frame.
  30.  
  31. Install or connect the following:

    New frame-to-body bolts and torque the bolts to 133 ft. lbs. (180 Nm)
     
    Water pump with a new gasket and torque the bolts to 124 inch lbs. (14 Nm)
     
    Water pump pulley and torque the bolts to 106 inch lbs. (12 Nm)
     
    Belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
     
    Power steering pump pulley
     
    Drive belt
     
    Underhood accessory wiring junction
     
    Coolant reservoir and torque the nuts to 30 inch lbs. (3 Nm)
     
    Battery and tray
     
    Right diagonal brace and torque the bolts to 35 ft. lbs. (47 Nm)
     
    Camshaft covers and torque the bolts to 80 inch lbs. (9 Nm)
     
    Negative battery cable
     

  32.  
  33. Refill the engine cooling system.
  34.  
  35. Refill the engine with new oil.
  36.  
  37. Start the vehicle and check for leaks, repair if necessary.
  38.  

Secondary Timing Chain
  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
     
    Thermostat housing for clearance (when working on the front cylinder head)
     
    Rocker arm cover and install a Camshaft Holding Fixture
     
    Camshaft Position (CMP) sensor
     
    Camshaft sprocket bolts
     

  6.  
  7. Install the timing chain/sprocket holding fixture on the cylinder head.
  8.  
  9. Evenly slide the secondary drive chain and sprockets off the camshafts.
  10.  

To install:

Click image to see an enlarged view

Fig. Correct sprocket alignment for secondary timing chain-3.5L engine

  1. Install the secondary timing chain on the sprockets, with the drive pins at the 12 o-clock positions.
  2.  
  3. Install the sprockets/chain assembly onto the camshafts, with the chain properly aligned on the tensioner.
  4.  
  5. Remove the sprocket holding fixture from the cylinder head.
  6.  
  7. Install the sprocket bolts and torque the bolts to 18 ft. lbs. (25 Nm) plus an additional 45 degree turn.
  8.  
  9. Remove the camshaft holding fixture.
  10.  
  11. Install or connect the following:

    Rocker arm cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Thermostat housing (if removed) and torque the bolts to 80 inch lbs. (9 Nm)
     
    CMP sensor and torque the bolts to 80 inch lbs. (9 Nm)
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the vehicle and check for leaks, repair if necessary.
  16.  

3.5L Engine
Primary Chain
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the camshaft covers.
  10.  
  11. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the flats on the rear of the camshafts are parallel with the camshaft cover sealing surface.
  12.  
  13. Install camshaft holding fixtures on both sets of camshafts. Turn the hex portion of the camshaft to align them for tool installation.
    NOTE
    When installed, the flats on the rear of the camshafts will be parallel with the camshaft cover sealing surface.

  14.  
  15. Remove or disconnect the following:

    Right diagonal brace
     
    Battery and tray
     
    Coolant reservoir
     
    Underhood accessory wiring junction block, move it aside
     
    Drive belt
     
    Power steering pump pulley
     
    Idler pulley and belt tensioner
     
    Water pump pulley
     
    Water pump drive belt shield
     
    Water pump
     

  16.  
  17. Support the engine cradle.
  18.  
  19. Remove the right side engine cradle bolts.
  20.  
  21. Lower the cradle.
  22.  
  23. Remove or disconnect the following:
    NOTE
    Note that each plug has an O-ring.


    NOTE
    Remove the lower bolt allowing the tensioner to swing down and expand.



    Crankshaft balancer
     
    Front cover
     
    Engine lift bracket from the front of the engine
     
    Camshaft Position (CMP) sensor
     
    Sprocket bolt from the exhaust camshaft on the right cylinder head to allow for clearance of the chain guide
     
    Four chain guide access plugs from the cylinder heads
     



    Primary chain tensioner
     



    Primary chain tensioner shoe, by removing the bolt, pushing the guide downward slightly and pulling it up through the cylinder head
     
    Primary chain from the right camshaft, allowing it to fall into the oil pump area
     
    Primary chain

    Click image to see an enlarged view

    Fig. Primary timing chain alignment marks-3.5L engine



    Click image to see an enlarged view

    Fig. Compressing the primary chain tensioner-3.5L engine



    Click image to see an enlarged view

    Fig. Apply RTV sealant to the 3 areas indicated before installing the front cover and gasket-3.5L engine

     

  24.  

To install:

  1. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the mark on the crankshaft is at the 4 o-clock position.
  2.  
  3. Rotate the balance shaft so the timing mark is at the 5 o-clock position.
    NOTE
    Be sure the painted links are facing the front of the engine.

  4.  
  5. Install the timing chain on the sprockets.
  6.  
  7. Center the mark on the left intake camshaft sprocket between the 2 painted links.
  8.  
  9. Verify that all of the timing marks are aligned.
  10.  
  11. Install the primary chain tensioner shoe. Torque the bolt to 22 ft. lbs. (30 Nm).
  12.  
  13. Compress the primary chain tensioner using the following sub-steps:
    1. Step 1: Rotate the ratchet release lever counterclockwise and hold it.
    2.  
    3. Step 2: Press the tensioner shoe in and hold it.
    4.  
    5. Step 3: Release the ratchet lever and slowly release the pressure on the shoe.
    6.  
    7. Step 4: Insert a pin through the hole in the lever as the lever moves to the first click. The ratchet should hold the shoe in the compressed position.
      NOTE
      Be sure the lever on the tensioner is facing you when installed.

    8.  

  14.  
  15. Install or connect the following:

    Primary chain tensioner and torque the bolts to 18 ft. lbs. (25 Nm); then, remove the chain tensioner pin
     
    Four chain guide access plugs and torque the plugs to 44 inch lbs. (5 Nm)
     
    Front engine lift bracket and torque the hex head bolt to 37 ft. lbs. (50 Nm) and the internal drive bolt to 18 ft. lbs. (25 Nm)
     
    CMP sensor and torque the bolts to 80 inch lbs. (9 Nm)
     

  16.  
  17. Remove the camshaft holding tools.
  18.  
  19. Install the rocker arm covers. Torque the bolts to 80 inch lbs. (9 Nm).
  20.  
  21. Place a small bead of RTV sealant on the 3 areas indicated in the diagram.
  22.  
  23. Install or connect the following:

    Front cover with a new gasket and torque the bolts to 124 inch lbs. (14 Nm) and the coolant drain plug to 89 inch lbs. (10 Nm)
     
    Crankshaft balancer and torque the bolt to 37 ft. lbs. (50 Nm) plus an additional 120 degree turn
     

  24.  
  25. Raise the engine cradle and install new bolts loosely.
  26.  
  27. Coat the sub-frame bushings with rubber lubricant.
  28.  
  29. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, 3 / 4 inches thick by 8 inches long through the alignment holes on the right side of the frame.
  30.  
  31. Install or connect the following:

    New frame-to-body bolts and torque the bolts to 133 ft. lbs. (180 Nm)
     
    Water pump with a new gasket and torque the bolts to 124 inch lbs. (14 Nm)
     
    Water pump pulley and torque the bolts to 106 inch lbs. (12 Nm)
     
    Belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
     
    Power steering pump pulley
     
    Drive belt
     
    Underhood accessory wiring junction
     
    Coolant reservoir and torque the nuts to 30 inch lbs. (3 Nm)
     
    Battery and tray
     
    Right diagonal brace and torque the bolts to 35 ft. lbs. (47 Nm)
     
    Camshaft covers and torque the bolts to 80 inch lbs. (9 Nm)
     
    Negative battery cable
     

  32.  
  33. Refill the engine cooling system.
  34.  
  35. Refill the engine with new oil.
  36.  
  37. Start the vehicle and check for leaks, repair if necessary.
  38.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the camshaft covers.
  10.  
  11. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the flats on the rear of the camshafts are parallel with the camshaft cover sealing surface.
  12.  
  13. Install camshaft holding fixtures on both sets of camshafts. Turn the hex portion of the camshaft to align them for tool installation.
    NOTE
    When installed, the flats on the rear of the camshafts will be parallel with the camshaft cover sealing surface.

  14.  
  15. Remove or disconnect the following:

    Right diagonal brace
     
    Battery and tray
     
    Coolant reservoir
     
    Underhood accessory wiring junction block, move it aside
     
    Drive belt
     
    Power steering pump pulley
     
    Idler pulley and belt tensioner
     
    Water pump pulley
     
    Water pump drive belt shield
     
    Water pump
     

  16.  
  17. Support the engine cradle.
  18.  
  19. Remove the right side engine cradle bolts.
  20.  
  21. Lower the cradle.
  22.  
  23. Remove or disconnect the following:
    NOTE
    Note that each plug has an O-ring.


    NOTE
    Remove the lower bolt allowing the tensioner to swing down and expand.



    Crankshaft balancer
     
    Front cover
     
    Engine lift bracket from the front of the engine
     
    Camshaft Position (CMP) sensor
     
    Sprocket bolt from the exhaust camshaft on the right cylinder head to allow for clearance of the chain guide
     
    Four chain guide access plugs from the cylinder heads
     



    Primary chain tensioner
     



    Primary chain tensioner shoe, by removing the bolt, pushing the guide downward slightly and pulling it up through the cylinder head
     
    Primary chain from the right camshaft, allowing it to fall into the oil pump area
     
    Primary chain

    Click image to see an enlarged view

    Fig. Primary timing chain alignment marks-3.5L engine



    Click image to see an enlarged view

    Fig. Compressing the primary chain tensioner-3.5L engine



    Click image to see an enlarged view

    Fig. Apply RTV sealant to the 3 areas indicated before installing the front cover and gasket-3.5L engine

     

  24.  

To install:

  1. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the mark on the crankshaft is at the 4 o-clock position.
  2.  
  3. Rotate the balance shaft so the timing mark is at the 5 o-clock position.
    NOTE
    Be sure the painted links are facing the front of the engine.

  4.  
  5. Install the timing chain on the sprockets.
  6.  
  7. Center the mark on the left intake camshaft sprocket between the 2 painted links.
  8.  
  9. Verify that all of the timing marks are aligned.
  10.  
  11. Install the primary chain tensioner shoe. Torque the bolt to 22 ft. lbs. (30 Nm).
  12.  
  13. Compress the primary chain tensioner using the following sub-steps:
    1. Step 1:Rotate the ratchet release lever counterclockwise and hold it.
    2.  
    3. Step 2:Press the tensioner shoe in and hold it.
    4.  
    5. Step 3:Release the ratchet lever and slowly release the pressure on the shoe.
    6.  
    7. Step 4:Insert a pin through the hole in the lever as the lever moves to the first click. The ratchet should hold the shoe in the compressed position.
      NOTE
      Be sure the lever on the tensioner is facing you when installed.

    8.  

  14.  
  15. Install or connect the following:

    Primary chain tensioner and torque the bolts to 18 ft. lbs. (25 Nm); then, remove the chain tensioner pin
     
    Four chain guide access plugs and torque the plugs to 44 inch lbs. (5 Nm)
     
    Front engine lift bracket and torque the hex head bolt to 37 ft. lbs. (50 Nm) and the internal drive bolt to 18 ft. lbs. (25 Nm)
     
    CMP sensor and torque the bolts to 80 inch lbs. (9 Nm)
     

  16.  
  17. Remove the camshaft holding tools.
  18.  
  19. Install the rocker arm covers. Torque the bolts to 80 inch lbs. (9 Nm).
  20.  
  21. Place a small bead of RTV sealant on the 3 areas indicated in the diagram.
  22.  
  23. Install or connect the following:

    Front cover with a new gasket and torque the bolts to 124 inch lbs. (14 Nm) and the coolant drain plug to 89 inch lbs. (10 Nm)
     
    Crankshaft balancer and torque the bolt to 37 ft. lbs. (50 Nm) plus an additional 120 degree turn
     

  24.  
  25. Raise the engine cradle and install new bolts loosely.
  26.  
  27. Coat the sub-frame bushings with rubber lubricant.
  28.  
  29. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, 3 / 4 inches thick by 8 inches long through the alignment holes on the right side of the frame.
  30.  
  31. Install or connect the following:

    New frame-to-body bolts and torque the bolts to 133 ft. lbs. (180 Nm)
     
    Water pump with a new gasket and torque the bolts to 124 inch lbs. (14 Nm)
     
    Water pump pulley and torque the bolts to 106 inch lbs. (12 Nm)
     
    Belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
     
    Power steering pump pulley
     
    Drive belt
     
    Underhood accessory wiring junction
     
    Coolant reservoir and torque the nuts to 30 inch lbs. (3 Nm)
     
    Battery and tray
     
    Right diagonal brace and torque the bolts to 35 ft. lbs. (47 Nm)
     
    Camshaft covers and torque the bolts to 80 inch lbs. (9 Nm)
     
    Negative battery cable
     

  32.  
  33. Refill the engine cooling system.
  34.  
  35. Refill the engine with new oil.
  36.  
  37. Start the vehicle and check for leaks, repair if necessary.
  38.  

Secondary Timing Chain
  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
     
    Thermostat housing for clearance (when working on the front cylinder head)
     
    Rocker arm cover and install a Camshaft Holding Fixture
     
    Camshaft Position (CMP) sensor
     
    Camshaft sprocket bolts
     

  6.  
  7. Install the timing chain/sprocket holding fixture on the cylinder head.
  8.  
  9. Evenly slide the secondary drive chain and sprockets off the camshafts.
  10.  

To install:

Click image to see an enlarged view

Fig. Correct sprocket alignment for secondary timing chain-3.5L engine

  1. Install the secondary timing chain on the sprockets, with the drive pins at the 12 o-clock positions.
  2.  
  3. Install the sprockets/chain assembly onto the camshafts, with the chain properly aligned on the tensioner.
  4.  
  5. Remove the sprocket holding fixture from the cylinder head.
  6.  
  7. Install the sprocket bolts and torque the bolts to 18 ft. lbs. (25 Nm) plus an additional 45 degree turn.
  8.  
  9. Remove the camshaft holding fixture.
  10.  
  11. Install or connect the following:

    Rocker arm cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Thermostat housing (if removed) and torque the bolts to 80 inch lbs. (9 Nm)
     
    CMP sensor and torque the bolts to 80 inch lbs. (9 Nm)
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the vehicle and check for leaks, repair if necessary.
  16.  

  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:

    Negative battery cable
     
    Thermostat housing for clearance (when working on the front cylinder head)
     
    Rocker arm cover and install a Camshaft Holding Fixture
     
    Camshaft position (CMP) sensor
     
    Camshaft sprocket bolts
     

  6.  
  7. Install the timing chain/sprocket holding fixture on the cylinder head.
  8.  
  9. Evenly slide the secondary drive chain and sprockets off the camshafts.
  10.  

To install:

Click image to see an enlarged view

Fig. Correct sprocket alignment for secondary timing chain-3.5L engine

  1. Install the secondary timing chain on the sprockets, with the drive pins at the 12 o-clock positions.
  2.  
  3. Install the sprockets/chain assembly onto the camshafts, with the chain properly aligned on the tensioner.
  4.  
  5. Remove the sprocket holding fixture from the cylinder head.
  6.  
  7. Install the sprocket bolts and torque the bolts to 18 ft. lbs. (25 Nm) plus an additional 45 degree turn.
  8.  
  9. Remove the camshaft holding fixture.
  10.  
  11. Install or connect the following:

    Rocker arm cover and torque the bolts to 80 inch lbs. (9 Nm)
     
    Thermostat housing (if removed) and torque the bolts to 80 inch lbs. (9 Nm)
     
    CMP sensor and torque the bolts to 80 inch lbs. (9 Nm)
     
    Negative battery cable
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Start the vehicle and check for leaks, repair if necessary.
  16.  

3.8L Engine


Click image to see an enlarged view

Fig. Exploded view of lower engine components-3.8L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the coolant system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Install an Engine Support Fixture.
  8.  
  9. Raise the engine so that the weight is removed from the engine mount.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Water pump pulley bolts
     
    Accessory drive belt(s)
     
    Drive belt tensioner
     
    Water pump pulley
     
    Crankshaft balancer
     
    Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connections
     
    Oil pressure sensor connection
     
    CKP sensor shield
     
    Engine mount bracket
     
    Front oil pan-to-front cover bolts
     
    Oil filter
     
    Lower radiator hose
     
    CKP sensor
     
    Front cover
     

  12.  
  13. Rotate the crankshaft until the timing mark on the camshaft sprocket is aligned with the crankshaft sprocket timing mark.

    Timing chain damper assembly
     
    Camshaft sprocket bolt
     
    Camshaft sprocket with the timing chain
     
    Crankshaft sprocket
     

  14.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the timing chain and sprockets-3.8L engines



Click image to see an enlarged view

Fig. Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment-3.8L engine

  1. Install the crankshaft sprocket.
    NOTE
    It may be necessary to use a gear installer to fully seat the gear. Be sure the timing mark on the crankshaft gear is pointing straight up.

  2.  
  3. Install the camshaft gear with the timing chain.
    NOTE
    Hold the sprocket with the timing mark facing downward and the chain hanging down off the sprocket; then, loop the chain under the crankshaft sprocket.

  4.  
  5. If the marks are not in alignment perform the following:
    1. Step 1: Remove the camshaft sprocket and timing chain.
    2.  
    3. Step 2: Install the camshaft sprocket onto the camshaft and rotate the camshaft until the camshaft and crankshaft marks are aligned.
    4.  
    5. Step 3: Remove the camshaft sprocket.
    6.  
    7. Step 4: Reinstall the assembly.
    8.  

  6.  
  7. Install or connect the following:

    Camshaft sprocket bolt and torque the bolt to 74 ft. lbs. (100 Nm) plus an additional 90 degree turn
     
    Timing chain damper and torque the mounting bolts to 16 ft. lbs. (22 Nm)
     
    Front cover seal lubricated with engine oil, using the appropriate seal driver
     
    New front cover gasket
     
    Front cover and torque the bolts to 15 ft. lbs. (20 Nm) plus an additional 40 degree turn
     
    Oil pan-to-front cover bolts and torque the bolts to 125 inch lbs. (14 Nm)
     
    CKP sensor and torque the bolts to 21 ft. lbs. (28 Nm)
     
    CKP sensor shield
     
    Engine mount bracket and torque the bolts to 65 ft. lbs. (87 Nm)
     
    Water pump pulley and torque the bolts to 115 inch lbs. (13 Nm)
     
    Lower radiator hose
     
    Oil filter
     
    Crankshaft balancer and torque the bolt to 111 ft. lbs. (150 Nm) plus an additional 75 degree turn
     
    Belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Negative battery cable
     

  8.  
  9. Remove the engine support fixture.
  10.  
  11. Refill the cooling system.
  12.  
  13. Refill the engine oil.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  



Click image to see an enlarged view

Fig. Exploded view of lower engine components-3.8L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the coolant system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Install an Engine Support Fixture.
  8.  
  9. Raise the engine so that the weight is removed from the engine mount.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Accessory drive belt(s)
     
    Drive belt tensioner
     
    Crankshaft balancer
     
    Crankshaft Position (CKP) sensor shield
     
    Engine mount bracket
     
    Front oil pan-to-front cover bolts
     
    Oil filter
     
    Lower radiator hose
     
    Water pump pulley
     
    CKP sensor
     
    Front cover
     

  12.  
  13. Rotate the crankshaft until the timing mark on the camshaft sprocket is aligned with the crankshaft sprocket timing mark.

    Timing chain damper assembly
     
    Camshaft sprocket bolt
     
    Camshaft sprocket with the timing chain
     
    Crankshaft sprocket
     

  14.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the timing chain and sprockets-3.8L engines



Click image to see an enlarged view

Fig. Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment-3.8L engine

  1. Install the crankshaft sprocket.
    NOTE
    It may be necessary to use a gear installer to fully seat the gear. Be sure the timing mark on the crankshaft gear is pointing straight up.

  2.  
  3. Install the camshaft gear with the timing chain.
    NOTE
    Hold the sprocket with the timing mark facing downward and the chain hanging down off the sprocket; then, loop the chain under the crankshaft sprocket.

  4.  
  5. If the marks are not in alignment perform the following:
    1. Step 1:Remove the camshaft sprocket and timing chain.
    2.  
    3. Step 2:Install the camshaft sprocket onto the camshaft and rotate the camshaft until the camshaft and crankshaft marks are aligned.
    4.  
    5. Step 3:Remove the camshaft sprocket.
    6.  
    7. Step 4:Reinstall the assembly.
    8.  

  6.  
  7. Install or connect the following:

    Camshaft sprocket bolt and torque the bolt to 74 ft. lbs. (100 Nm) plus an additional 90 degree turn
     
    Timing chain damper and torque the mounting bolts to 16 ft. lbs. (22 Nm)
     
    Front cover seal lubricated with engine oil, using the appropriate seal driver
     
    New front cover gasket
     
    Front cover and torque the bolts to 15 ft. lbs. (20 Nm) plus an additional 40 degree turn
     
    Oil pan-to-front cover bolts and torque the bolts to 125 inch lbs. (14 Nm)
     
    CKP sensor and torque the bolts to 21 ft. lbs. (28 Nm)
     
    CKP sensor shield
     
    Engine mount bracket and torque the bolts to 65 ft. lbs. (87 Nm)
     
    Water pump pulley and torque the bolts to 115 inch lbs. (13 Nm)
     
    Lower radiator hose
     
    Oil filter
     
    Crankshaft balancer and torque the bolt to 111 ft. lbs. (150 Nm) plus an additional 75 degree turn
     
    Belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Negative battery cable
     

  8.  
  9. Remove the engine support fixture.
  10.  
  11. Refill the cooling system.
  12.  
  13. Refill the engine oil.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  



Click image to see an enlarged view

Fig. Exploded view of lower engine components-3.8L engine

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the coolant system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Install an Engine Support Fixture.
  8.  
  9. Raise the engine so that the weight is removed from the engine mount.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Water pump pulley bolts
     
    Accessory drive belt(s)
     
    Drive belt tensioner
     
    Water pump pulley
     
    Crankshaft balancer
     
    Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connections
     
    Oil pressure sensor connection
     
    CKP sensor shield
     
    Engine mount bracket
     
    Front oil pan-to-front cover bolts
     
    Oil filter
     
    Lower radiator hose
     
    CKP sensor
     
    Front cover
     

  12.  
  13. Rotate the crankshaft until the timing mark on the camshaft sprocket is aligned with the crankshaft sprocket timing mark.

    Timing chain damper assembly
     
    Camshaft sprocket bolt
     
    Camshaft sprocket with the timing chain
     
    Crankshaft sprocket
     

  14.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the timing chain and sprockets-3.8L engines



Click image to see an enlarged view

Fig. Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment-3.8L engine

  1. Install the crankshaft sprocket.
    NOTE
    It may be necessary to use a gear installer to fully seat the gear. Be sure the timing mark on the crankshaft gear is pointing straight up.

  2.  
  3. Install the camshaft gear with the timing chain.
    NOTE
    Hold the sprocket with the timing mark facing downward and the chain hanging down off the sprocket; then, loop the chain under the crankshaft sprocket.

  4.  
  5. If the marks are not in alignment perform the following:
    1. Step 1: Remove the camshaft sprocket and timing chain.
    2.  
    3. Step 2: Install the camshaft sprocket onto the camshaft and rotate the camshaft until the camshaft and crankshaft marks are aligned.
    4.  
    5. Step 3: Remove the camshaft sprocket.
    6.  
    7. Step 4: Reinstall the assembly.
    8.  

  6.  
  7. Install or connect the following:

    Camshaft sprocket bolt and torque the bolt to 74 ft. lbs. (100 Nm) plus an additional 90 degree turn
     
    Timing chain damper and torque the mounting bolts to 16 ft. lbs. (22 Nm)
     
    Front cover seal lubricated with engine oil, using the appropriate seal driver
     
    New front cover gasket
     
    Front cover and torque the bolts to 15 ft. lbs. (20 Nm) plus an additional 40 degree turn
     
    Oil pan-to-front cover bolts and torque the bolts to 125 inch lbs. (14 Nm)
     
    CKP sensor and torque the bolts to 21 ft. lbs. (28 Nm)
     
    CKP sensor shield
     
    Engine mount bracket and torque the bolts to 65 ft. lbs. (87 Nm)
     
    Water pump pulley and torque the bolts to 115 inch lbs. (13 Nm)
     
    Lower radiator hose
     
    Oil filter
     
    Crankshaft balancer and torque the bolt to 111 ft. lbs. (150 Nm) plus an additional 75 degree turn
     
    Belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Accessory drive belt
     
    Negative battery cable
     

  8.  
  9. Remove the engine support fixture.
  10.  
  11. Refill the cooling system.
  12.  
  13. Refill the engine oil.
  14.  
  15. Start the engine and check for leaks, repair if necessary.
  16.  

 
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