Crossfire 2006-2008

Timing Chain & Sprockets

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the power steering pump fluid.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Radiator fan
     
    Accessory drive belt
     
    Idler pulley
     
    Accessory drive belt tensioner
     
    Vibration damper
     
    Coolant and heater hoses from water pump
     
    Power steering pump
     
    AIR pump
     
    Cylinder head covers
     
    Front cylinder head to timing chain cover retaining bolts
     
    Alternator
     

  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the lower oil pan.
  12.  
  13. Remove the upper oil pan.
  14.  
  15. Remove the starter.
  16.  
  17. Rotate crankshaft to 40 degrees After Top Dead Center (ATDC).
  18.  
  19. Lock the flywheel in place using Special Tool 9102 by inserting the tool into the starter opening.
  20.  
  21. Remove or disconnect the following:

    Timing chain tensioner
     
    Timing chain cover
     
    Oil pump drive chain and tensioner
     
    Left and right camshaft sprocket bolts
     
    Timing chain and camshaft sprockets
     
    Timing chain camshaft sprocket
     
    Rear main seal
     

  22.  
  23. Hold the balance shaft rear counter weight using a drift, and remove the rear retaining bolt.
  24.  
  25. Remove the balance shaft counterweight.
  26.  
  27. Remove the balance shaft locking plate at the front of the engine block.
  28.  
  29. Remove the balance shaft.

    Click image to see an enlarged view

    Fig. Crankshaft timing mark set to 40 degrees ATDC



    Click image to see an enlarged view

    Fig. Locking the flywheel in place with tool 9102

  30.  
  31. Pry out the front crankshaft seal using a suitable pry tool.

    Click image to see an enlarged view

    Fig. Exploded view of timing chain and balance shaft assembly

  32.  

To install:

Click image to see an enlarged view

Fig. Positioning crankshaft front seal into Seal Installer 9103

  1. Position the front crankshaft seal into Special Tool 9103 as shown.
  2.  
  3. Align the slot of the installation tool into the crankshaft keyway.
  4.  
  5. Tap the tool in until the crankshaft damper bolt can be inserted.
  6.  
  7. Tighten the damper bolt until the seal is installed.
  8.  
  9. Remove the installer tool.
  10.  
  11. Place the balance shaft into the bore in the block from the front of the engine.
  12.  
  13. Install the rear counter weight onto the shaft and torque the retaining bolt to 15 ft. lbs. (20 Nm), plus an additional 90 degrees.
  14.  
  15. Install the balance shaft locking plate and bolt and torque to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the rear crankshaft seal/end cover assembly.
  18.  
  19. Install the crankshaft sprocket.
  20.  
  21. Ensure that the crankshaft is still positioned at 40 degrees ATDC.
  22.  
  23. Align the balance shaft sprocket with the timing chain (3) and check that the copper teeth (1) of the timing chain are aligned on the camshaft sprockets (6).
  24.  
  25. Route the timing chain within the timing chain guides as shown.
  26.  
  27. Lock the camshafts in place with Camshaft Locking Plates 9104 and 9105.

    Click image to see an enlarged view

    Fig. Positioning timing chain on camshaft sprockets



    Click image to see an enlarged view

    Fig. Timing chain guide locations



    Click image to see an enlarged view

    Fig. Camshaft locking plate

  28.  
  29. Install the oil pump drive chain and tensioner.
  30.  
  31. Apply sealant to timing chain cover as shown.

    Click image to see an enlarged view

    Fig. Applying sealant to front cover

  32.  
  33. Install or connect the following:

    Timing chain cover. Torque the bolts to 15 ft. lbs. (20 Nm).
     
    Timing chain tensioner. Torque the bolt to 59 ft. lbs. (80 Nm).
     

  34.  
  35. Remove Special Tool 9102 to unlock the flywheel.
  36.  
  37. Install or connect the following:

    Starter
     
    Upper and lower oil pans
     
    Alternator
     
    Front cylinder head to timing chain cover bolts. Tighten to 15 ft. lbs. (20 Nm).
     
    Cylinder head covers
     
    AIR pump
     
    Power steering pump
     
    Coolant and heater hoses to water pump
     
    Vibration damper. Tighten to 148 ft. lbs. (200 Nm) plus 90 degrees clockwise.
     
    Idler pulley
     
    Accessory belt tensioner
     
    Accessory drive belt
     
    Radiator fan
     
    Negative battery cable
     

  38.  
  39. Fill the power steering pump with fluid.
  40.  
  41. Fill and bleed the cooling system.
  42.  

 
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