G6 2005-2007

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



2.4L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the drive belts.
    NOTE
    If only the crankshaft front seal is being replaced, go to steps 9, 10 and 11.

  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove the no. 1 cylinder spark plug.
  12.  
  13. Rotate the crankshaft in the engine rotational direction clockwise, until the no. 1 piston is at TDC on the compression stroke.
  14.  
  15. Remove the camshaft cover.
  16.  
  17. Hold the crankshaft from turning and remove and discard the crankshaft balancer bolt.
  18.  
  19. Remove the crankshaft balancer.
  20.  
  21. If only the front seal is being replaced, use a flat-bladed too and pry the oil seal from the front cover. Press in a new seal with a seal installer. Install the crankshaft balancer using a new bolt and tighten to 74 ft. lbs. (100 Nm) plus an additional 125 degrees.
  22.  
  23. Remove the drive belt tensioner.
  24.  
  25. Remove the engine front cover-to-water pump bolt.
  26.  
  27. Remove the remaining engine front cover bolts.
  28.  
  29. Remove the engine front cover.
  30.  
  31. Remove the upper timing chain guide bolts and guide.
  32.  
  33. Remove the timing chain tensioner.
  34.  
  35. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
  36.  
  37. Remove and discard the exhaust camshaft actuator bolt.
  38.  
  39. Remove the exhaust camshaft actuator from the camshaft and timing chain.
  40.  
  41. Remove the timing chain tensioner guide bolt and guide.
  42.  
  43. Remove the fixed timing chain guide access plug.
  44.  
  45. Remove the fixed timing chain guide bolts and guide.
  46.  
  47. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
  48.  
  49. Remove and discard the intake camshaft actuator bolt.
  50.  
  51. Remove the intake camshaft actuator, and the timing chain through the top of the cylinder head.
  52.  
  53. Remove the timing chain crankshaft sprocket.
  54.  
  55. Remove the balance shaft drive chain tensioner bolts and tensioner.
  56.  
  57. Remove the adjustable balance shaft chain guide bolt and guide.
  58.  
  59. Remove the small balance shaft drive chain guide bolts and guide.
  60.  
  61. Remove the upper balance shaft drive chain guide bolts and guide.
  62.  
  63. Remove the balance shaft drive chain.
  64.  
  65. Remove the balance shaft drive sprocket.
  66.  

To install:

  1. Be sure all sealing surfaces are clean and prepared for assembly.
    CAUTION
    If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise.

  2.  
  3. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are three colored links on the chain. Two are chrome and one is copper. Use the following steps in order to line up the links with the sprockets.
    1. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket.
    2.  
    3. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket).
    4.  
    5. Place the chain (7) on the water pump drive sprocket. The alignment is not critical.
    6.  
    7. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.

      Click image to see an enlarged view

      Fig. Installing balance shaft timing chain-2.4L engine

    8.  

  4.  
  5. Install the upper balance shaft drive chain guide and bolts and tighten to 11 ft. lbs. (15 Nm).
  6.  
  7. Install the small balance shaft drive chain guide and bolts and tighten to 11 ft. lbs. (15 Nm).
  8.  
  9. Install the adjustable balance shaft chain guide and bolt and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Reset the timing chain tensioner by performing the following steps:.
    1. Rotate the tensioner plunger 90 degrees in its bore and compress the plunger.
    2.  
    3. Rotate the tensioner back to the original 12 o' clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
    4.  

  12.  
  13. Install the balance shaft drive chain tensioner and bolts and tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Remove the paper clip from the balance shaft drive chain tensioner.
  16.  
  17. Install the timing chain crankshaft sprocket to the crankshaft with the timing mark in the 5 o'clock position,
    NOTE
    There are 3 colored links on the timing chain. Two links are pink in color and one link is blue in color. Use the following procedure to line up the links with the sprockets. Orient the chain so that the colored links are visible.

  18.  
  19. Assemble the intake camshaft actuator to the timing chain with the timing mark lined up with the blue colored link (1). Install and hand tighten a new intake camshaft actuator bolt.

    Click image to see an enlarged view

    Fig. Aligning timing chain link with the intake camshaft actuator-2.4L engine

  20.  
  21. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses.
  22.  
  23. Route the timing chain around the crankshaft sprocket and line up the first pink link with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.

    Click image to see an enlarged view

    Fig. Aligning timing chain link with the crankshaft sprocket-2.4L engine

  24.  
  25. Install the adjustable timing chain guide through the opening in the cylinder head. Install the adjustable timing chain bolt and tighten to 89 inch lbs. (10 Nm).
  26.  
  27. Install the exhaust camshaft actuator and a new bolt loosely onto the exhaust camshaft.
  28.  
  29. Align the timing mark on the actuator with the last pink colored link. Tighten the bolt finger tight.

    Click image to see an enlarged view

    Fig. Aligning timing chain link with the exhaust camshaft actuator-2.4L engine

  30.  
  31. If the camshaft is 180 degrees out of time, use a 24-mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft actuator seats in the notch in the front of the intake camshaft.
  32.  
  33. Turn the crankshaft 45 degrees in either direction.
  34.  
  35. Turn the intake cam to the appropriate location.
  36.  
  37. Turn the crankshaft back to TDC.
  38.  
  39. When the actuator seats on the cam, tighten the actuator bolt hand tight.
  40.  
  41. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
  42.  
  43. Install the fixed timing chain guide and bolts and tighten to 89 inch lbs. (10 Nm).
  44.  
  45. Install the upper timing chain guide and bolts and tighten to 89 inch lbs. (10 Nm).
  46.  
  47. Install a 24 mm wrench onto the hex on the intake camshaft. Using a torque wrench, tighten the camshaft actuator bolt to 63 ft. lbs. (85 Nm), plus an additional 30 degrees.
  48.  
  49. Install a 24 mm wrench onto the hex on the exhaust camshaft. Using a torque wrench, tighten the camshaft actuator bolt to 63 ft. lbs. (85 Nm), plus an additional 30 degrees.
  50.  
  51. Remove the old oil from the timing chain tensioner.
  52.  
  53. Inspect the timing chain tensioner. If the timing tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
  54.  
  55. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inch (72mm) from end to end. A tensioner in the active state will measure 3.35 inch (85mm) from end to end.
  56.  
  57. If the timing chain tensioner is not in the compressed state, perform the following steps:
    1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
    2.  
    3. Install the J 45027-2 (2) into a vise.
    4.  
    5. Install the notch end of the piston assembly into the J 45027-2 (2).
    6.  
    7. Using the J 45027-1 (1), turn the ratchet cylinder into the piston.

      Click image to see an enlarged view

      Fig. Compressing the timing chain tensioner-2.4L engine

    8.  

  58.  
  59. Install the compressed piston assembly back into the timing chain tensioner body until the assembly stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, the assembly will activate the tensioner, which will then need to be reset again.
  60.  
  61. At this point the tensioner should measure approximately 2.83 inch (72mm) from end to end.
  62.  
  63. Ensure that all dirt and debris are removed from the timing chain tensioner threaded hole in the cylinder head.
  64.  
  65. Install the timing chain tensioner and tighten to 66 ft. lbs. (75 Nm).
  66.  
  67. The timing chain tensioner is released by compressing the tensioner 0.079 inch (2mm) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
  68.  
  69. Apply sealant to the threads and install the timing chain guide bolt access hole plug and tighten to 59 ft. lbs. (80 Nm).
  70.  
  71. Position and install the engine front cover.
  72.  
  73. Install the engine front cover-to-water pump bolt and tighten to 18 ft. lbs. (25 Nm).
  74.  
  75. Install the engine front cover bolts and tighten to 18 ft. lbs. (25 Nm).
  76.  
  77. Install the drive belt tensioner bolt and tighten to 33 ft. lbs. (45 Nm).
  78.  
  79. Install the crankshaft balancer using a new bolt and tighten to 74 ft. lbs. (100 Nm) plus an additional 125 degrees.
  80.  
  81. Install the camshaft cover.
  82.  
  83. Install the no. 1 cylinder spark plug.
  84.  
  85. Fill the engine oil.
  86.  
  87. Install the drive belts.
  88.  
  89. Connect the negative battery cable
  90.  
  91. Fill and bleed the cooling system.
  92.  
  93. Start the vehicle, check for leaks and repair if necessary.
  94.  

3.5L Engine

NOTE
If only the crankshaft front seal is being replaced, perform steps 1 through 18.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the engine oil and cooling system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the drive belt.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the right front tire and wheel.
  12.  
  13. Remove the right engine splash shield.
  14.  
  15. Install the jack stands to the frame.
  16.  
  17. Loosen the left frame bolts and remove the right side frame bolts.
  18.  
  19. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
  20.  
  21. Remove the torque converter covers.
  22.  
  23. Remove the oil pan.
  24.  
  25. Lock flywheel to prevent rotation.
  26.  
  27. Remove the crankshaft balancer bolt and the washer.
  28.  
  29. Remove the crankshaft balancer using a 3-jaw puller.
  30.  
  31. Remove the crankshaft key from the keyway.
  32.  
  33. Pry out the oil seal using a large screwdriver or the equivalent.
  34.  
  35. If only the oil seal is being replaced, lubricate the new oil seal using clean engine oil. Insert the oil seal into the front cover with the lip facing the engine and seat the seal. Install the crankshaft key into the keyway. Install the crankshaft balancer and tighten the bolt to 118 ft. lbs. (160 Nm). Reverse the removal procedure.
  36.  
  37. Remove the thermostat bypass pipe from the engine front cover.
  38.  
  39. Remove the radiator outlet hose from the engine front cover.
  40.  
  41. Remove the water pump from the engine front cover.
  42.  
  43. Remove the CKP sensor wiring harness bracket.
  44.  
  45. Remove the engine front cover bolts.
  46.  
  47. Remove the engine front cover.
  48.  
  49. Remove the engine front cover gasket.
  50.  
  51. Clean and inspect the engine front cover.
  52.  
  53. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield and the water pump.
  54.  
  55. Rotate the crankshaft until the timing marks in the following locations are aligned: The camshaft alignment pin (4) to the timing chain dampener (3). The timing chain dampener (1) to the crankshaft sprocket (2).

    Click image to see an enlarged view

    Fig. Aligning the timing chain marks-3.5L engine

  56.  
  57. Remove the camshaft sprocket bolt.
  58.  
  59. Remove the camshaft sprocket with the timing chain.
  60.  
  61. Remove the crankshaft sprocket.
  62.  
  63. Remove the timing chain dampener bolts and dampener.
  64.  
  65. If necessary, remove the camshaft thrust plate.
  66.  
  67. Clean and inspect the timing chain and the gears.
  68.  

To install:

  1. If removed, install the camshaft thrust plate and tighten to 89 inch lbs. (10 Nm).
  2.  
  3. Install the crankshaft sprocket.
  4.  
  5. Apply engine oil supplement to the sprocket thrust surface.
  6.  
  7. Install the timing chain dampener and tighten the bolts to 15 ft. lbs. (21 Nm).
  8.  
  9. Install the timing chain onto the camshaft gear.
  10.  
  11. Hold the camshaft sprocket with the chain hanging down, and install the chain to the crankshaft gear.
  12.  
  13. Align the chain and sprocket timing marks.
  14.  
  15. Install the camshaft sprocket bolt and tighten to 103 ft. lbs. (140 Nm) to draw the sprocket onto the camshaft.
  16.  
  17. Coat the crankshaft and camshaft sprocket with engine oil.
  18.  
  19. If removed install the water pump and drive belt shield to the front cover.
  20.  
  21. Apply sealant to both sides of the lower tabs of the engine front cover gasket.
  22.  
  23. Install the engine front cover gasket.
  24.  
  25. Install the front cover.
  26.  
  27. Apply sealant to the bolt hole locations shown.

    Click image to see an enlarged view

    Fig. Engine front cover sealant locations-3.5L engine

  28.  
  29. Install the engine front cover bolts and tighten the small engine front cover bolts (1) to 20 ft. lbs. (27 Nm). Tighten the large engine front cover bolts (2, 3) to 41 ft. lbs. (55 Nm).

    Click image to see an enlarged view

    Fig. Engine front cover bolt identification-3.5L engine

  30.  
  31. Install the radiator outlet hose to the engine front cover.
  32.  
  33. Install the thermostat bypass pipe to the engine front cover.
  34.  
  35. Apply sealant to the keyway of the crankshaft balancer.
  36.  
  37. Install the crankshaft balancer using Balancer Installer J-29113.
  38.  
  39. Install the crankshaft balancer washer and the bolt and tighten to 118 ft. lbs. (160 Nm).
  40.  
  41. Remove the lock from the flywheel.
  42.  
  43. Install the torque converter covers.
  44.  
  45. Raise the frame to the original position.
  46.  
  47. Install and tighten the frame bolts to 73 ft. lbs. (100 Nm), plus an additional 180 degrees.
  48.  
  49. Install the oil pan.
  50.  
  51. Install the right engine splash shield.
  52.  
  53. Install the right front tire and wheel.
  54.  
  55. Lower the vehicle.
  56.  
  57. Install the drive belt.
  58.  
  59. Fill the engine with clean oil.
  60.  
  61. Fill and bleed the cooling system.
  62.  
  63. Start the engine and check for proper operation.
  64.  

3.6L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the drive belts.
  6.  
  7. Remove the spark plugs in order to ease crankshaft/engine rotation.
  8.  
  9. Remove the lower intake manifold.
  10.  
  11. Remove the camshaft covers.
  12.  
  13. Drain the engine coolant.
  14.  
  15. Remove the drive belt tensioner.
  16.  
  17. Remove the water pump.
  18.  
  19. Remove the power steering pump and position aside.
  20.  
  21. Install the engine support fixture.
  22.  
  23. Remove the crankshaft balancer.
  24.  
  25. Remove the camshaft position actuator valves from the front cover.
  26.  
  27. Remove the camshaft position actuator solenoid valves from the front cover.
  28.  
  29. Remove the engine coolant thermostat housing.
  30.  
  31. Remove the engine oil pan.
  32.  
  33. Remove the engine front cover bolts.
  34.  
  35. Using the special camshaft locking tool EN 46111 , rotate the crankshaft until the left cylinder head camshafts align with the EN 46105-2 tool and the right cylinder head camshafts align with the EN 46105-1.

    Click image to see an enlarged view

    Fig. Rotating crankshaft with tool EN 46111for camshaft alignment-3.6L engine



    Click image to see an enlarged view

    Fig. Right camshaft alignment shown with tool EN 46105-1 left similar

  36.  
  37. Install the EN 46105-1 to the right camshafts.
  38.  
  39. Install the EN 46105-2 to the left camshafts.
  40.  
  41. Remove the right secondary camshaft drive chain from the right camshaft position actuators and the right camshaft intermediate drive chain idler sprocket.
  42.  
  43. Remove the primary camshaft drive chain.
  44.  
  45. Remove the left secondary camshaft drive chain tensioner bolts.
  46.  
  47. Remove the left secondary camshaft drive chain tensioner.
  48.  
  49. Remove and discard the left secondary camshaft drive chain tensioner gasket.
    NOTE
    Inspect the left secondary camshaft drive chain tensioner mounting surface on the left cylinder head for burrs or any defects that would degrade the sealing of the new left secondary camshaft drive chain tensioner gasket.

  50.  
  51. Remove the left secondary camshaft drive chain shoe bolt.
  52.  
  53. Remove the left secondary camshaft drive chain shoe.
  54.  
  55. Remove the left secondary camshaft drive chain guide bolts.
  56.  
  57. Remove the left secondary camshaft drive chain guide.
  58.  
  59. Remove the left camshaft intermediate drive chain idler bolt
  60.  
  61. Remove the left camshaft intermediate drive chain idler.
  62.  
  63. Remove the left secondary camshaft drive chain from the left camshaft position actuators and the left camshaft intermediate drive chain idler sprocket.
  64.  
  65. Clean and inspect all of the camshaft timing drive components.
  66.  

To install:


WARNING
All camshafts must be locked in place before installation of any camshaft drive chains.

  1. Ensure that the EN 46105-1 is fully seated onto the camshafts.
  2.  
  3. Ensure the crankshaft is in the stage one timing position with the crankshaft sprocket timing mark (1) aligned to the stage one timing mark on the oil pump cover (2) using the EN-48589.

    Click image to see an enlarged view

    Fig. Crankshaft sprocket (1) and oil pump (2) alignment marks

  4.  
  5. Install the left secondary camshaft drive chain.
  6.  
  7. Place the left secondary camshaft drive chain around the inner sprocket of the left camshaft intermediate drive chain idler with the timing camshaft drive chain link (1) aligned to the alignment access hole (2) made in the left camshaft intermediate drive chain idler outer sprocket.

    Click image to see an enlarged view

    Fig. Left camshaft intermediate drive chain idler outer sprocket and chain alignment.

  8.  
  9. Wrap the secondary camshaft drive chain around both left actuator drive sprockets.
  10.  
  11. Ensure there are 10 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets.

    Click image to see an enlarged view

    Fig. 10 links (1) alignment view

  12.  
  13. Align the left exhaust camshaft position actuator sprocket alignment circle mark (2) with the timing camshaft drive chain link (1).
  14.  
  15. Align the left intake camshaft position actuator sprocket alignment circle mark (1) with the timing camshaft drive chain link (2).

    Click image to see an enlarged view

    Fig. Exhaust camshaft alignment marks



    Click image to see an enlarged view

    Fig. Intake camshaft alignment marks

  16.  
  17. Ensure that the left camshaft intermediate drive chain idler is being installed. The recessed hub and the larger sprocket of the left camshaft intermediate drive chain idler is installed outward. The raised hub and the smaller sprocket of the left camshaft intermediate drive chain idler is installed towards the block.
  18.  
  19. Place the left camshaft intermediate drive chain idler to the cylinder block.
  20.  
  21. Install the camshaft intermediate drive chain idler bolt and tighten to 43 ft. lbs. (58 Nm).
  22.  
  23. Position the left secondary camshaft drive chain guide.
  24.  
  25. Install the secondary camshaft drive chain guide bolts and tighten to 17 ft. lbs. (23 Nm).
  26.  
  27. Position the left secondary camshaft drive chain shoe.
  28.  
  29. Install the secondary camshaft drive chain shoe bolt and tighten to 17 ft. lbs. (23 Nm).
  30.  
  31. Using the J 45027 , reset the left secondary camshaft drive chain tensioner plunger.
  32.  
  33. Install the plunger into the left secondary camshaft drive chain tensioner body.
  34.  
  35. Compress the plunger into the body and lock the left secondary camshaft drive chain tensioner by inserting the EN 46112 into the access hole in the side of the left secondary camshaft drive chain tensioner body.
  36.  
  37. Slowly release pressure on the left secondary camshaft drive chain tensioner. The left secondary camshaft drive chain tensioner should remain compressed.
  38.  
  39. Install a NEW left secondary camshaft drive chain tensioner gasket to the left secondary camshaft drive chain tensioner.
  40.  
  41. Install the left secondary camshaft drive chain tensioner bolts through the left secondary camshaft drive chain tensioner and gasket.
  42.  
  43. Ensure the left secondary camshaft drive chain tensioner mounting surface on the left cylinder head does not have any burrs or defects that would degrade the sealing of the NEW left secondary camshaft drive chain tensioner gasket.
  44.  
  45. Place the left secondary camshaft drive chain tensioner into position and loosely install the bolts to the block.
  46.  
  47. Verify the proper placement of the left secondary camshaft drive chain tensioner gasket tab.
  48.  
  49. Tighten the left secondary camshaft drive chain tensioner bolts in two steps:
    1. Tighten tensioner bolts to 44 inch. lbs. (5 Nm).
    2.  
    3. Tighten tensioner bots an additional 17 ft. lbs.(23 Nm).
    4.  

  50.  
  51. Release the left secondary camshaft drive chain tensioner by pulling out the EN 46112 pin and unlocking the tensioner plunger.
  52.  
  53. Verify the left secondary camshaft drive chain timing mark alignments.
    WARNING
    Ensure that the crankshaft is in the stage one timing drive assembly position.



    Click image to see an enlarged view

    Fig. Left secondary camshaft drive chain timing mark alignments (1-6)

  54.  
  55. Install the primary camshaft drive chain.
  56.  
  57. Wrap the primary camshaft drive chain around the large sprockets of each camshaft intermediate drive chain idler and the crankshaft sprocket.
  58.  
  59. The left camshaft intermediate drive chain idler timing mark (1) will align with a timing camshaft drive chain link (2
  60.  
  61. The right camshaft intermediate drive chain idler timing mark (2) will align with a timing camshaft drive chain link (1).
  62.  
  63. The crankshaft sprocket timing mark (2) will align with a timing camshaft drive chain link (1).
  64.  
  65. Ensure all the timing marks (2, 3, and 6) are properly aligned with the timing camshaft drive chain links (1, 4, and 5).

    Click image to see an enlarged view

    Fig. Primary chain alignment marks

  66.  
  67. Ensure that the crankshaft is in the stage 2 timing drive assembly position (1).
  68.  
  69. Install the right secondary camshaft drive chain.
  70.  
  71. 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.
  72.  
  73. Wrap the secondary camshaft drive chain around both right actuator drive sprockets.
  74.  
  75. Ensure there are 10 links (1) between the timing camshaft drive chain links for the camshaft position actuator sprockets
  76.  
  77. Align the right exhaust camshaft position actuator sprocket alignment triangle mark (1) with the timing camshaft drive chain link (2).
  78.  
  79. Align the right intake camshaft position actuator sprocket alignment triangle mark (2) with the timing camshaft drive chain link (1).
  80.  
  81. There will be 22 links (1) between the right camshaft intermediate drive chain idler timing camshaft drive chain link and each right camshaft position actuator sprocket timing camshaft drive chain link.

    Click image to see an enlarged view

    Fig. Secondary drive chain alignment marks



    Click image to see an enlarged view

    Fig. Timing drive chain alignment diagram (Fourth Design)-3.6L engine

  82.  
  83. Install the 0.315 inch. (8 mm) guide pins from the EN 46109 into the cylinder block.
  84.  
  85. Install the engine front cover to cylinder block seal.
  86.  
  87. Place a 3 mm (0.118 in) bead of RTV sealant, or equivalent, on the engine front cover.
  88.  
  89. Place the engine front cover onto the guide pins EN 46109 and slide into position.
  90.  
  91. Remove the EN 46109 guide pins.
  92.  
  93. Hand start all the front cover bolts.
  94.  
  95. Tighten the engine front cover bolts in sequence to 17 ft. lbs. (23 Nm).

    Click image to see an enlarged view

    Fig. Engine front cover tightening sequence-3.6L engine

  96.  
  97. Install the engine oil pan.
  98.  
  99. Install the engine coolant thermostat housing.
  100.  
  101. Remove the engine mount bracket.
  102.  
  103. Install the camshaft position actuator solenoid valves from the front cover.
  104.  
  105. Install the camshaft position actuator valves from the front cover.
  106.  
  107. Install the crankshaft balancer.
  108.  
  109. Install the power steering pump and position aside.
  110.  
  111. Install the water pump.
  112.  
  113. Install the drive belt tensioner.
  114.  
  115. Install drive belt.
  116.  
  117. Install the camshaft covers.
  118.  
  119. Install the lower intake manifold.
  120.  
  121. Refill crankcase with recommended motor oil.
  122.  
  123. Fill and bleed the cooling system.
  124.  
  125. Start the engine and check for proper operation.
  126.  

3.9L Engine

NOTE
If only the crankshaft front seal is being replaced, perform steps 1 through 18.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the engine oil and cooling system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the drive belt and drive belt tensioner.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Remove the right front tire and wheel.
  12.  
  13. Remove the right engine splash shield.
  14.  
  15. Install the jack stands to the frame.
  16.  
  17. Loosen the left frame bolts and remove the right side frame bolts.
  18.  
  19. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
  20.  
  21. Remove the torque converter covers.
  22.  
  23. Remove the oil pan.
  24.  
  25. Lock flywheel to prevent rotation.
  26.  
  27. Remove the crankshaft balancer bolt and the washer.
  28.  
  29. Remove the crankshaft balancer using a 3-jaw puller.
  30.  
  31. Remove the crankshaft key from the keyway.
  32.  
  33. Pry out the oil seal using a large screwdriver or the equivalent.
  34.  
  35. If only the oil seal is being replaced, lubricate the new oil seal using clean engine oil. Insert the oil seal into the front cover with the lip facing the engine and seat the seal. Install the crankshaft key into the keyway. Install the crankshaft balancer and tighten the bolt to 52 ft. lbs. (70 Nm), plus an additional 70 degrees. Reverse the removal procedure.
  36.  
  37. Remove the intake manifold cover.
  38.  
  39. Remove the air cleaner assembly.
  40.  
  41. Remove the engine mount strut bracket.
  42.  
  43. Disconnect the camshaft position actuator magnet electrical connector.
  44.  
  45. Remove the crankshaft position actuator magnet.
  46.  
  47. Remove the thermostat housing.
  48.  
  49. Remove the water pump.
  50.  
  51. Remove the engine front cover bolts.
  52.  
  53. Remove the engine front cover and gasket.
  54.  
  55. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2). Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).

    Click image to see an enlarged view

    Fig. Aligning the timing chain marks-3.9L engine

  56.  
  57. Remove the camshaft sprocket bolts.
  58.  
  59. Remove the timing chain, camshaft, and crankshaft sprockets.
  60.  
  61. Remove the timing chain tensioner.
  62.  
  63. Remove and discard the camshaft position actuator filter from the end of the camshaft.
  64.  

To install:

  1. Install a new camshaft position actuator filter to the end of the camshaft.
  2.  
  3. Install the crankshaft sprocket.
  4.  
  5. Apply prelube to the crankshaft sprocket thrust surface.
  6.  
  7. Install the timing chain tensioner and tighten the bolts to 15 ft. lbs. (20 Nm).
  8.  
  9. Using Tensioner Compressor EN-47719, fully collapse the tensioner, and place the tensioner retaining pin into the retaining hole.
  10.  
  11. Align the timing marks and hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
  12.  
  13. Align the dowel in the camshaft sprocket with the dowel hole in the camshaft.
  14.  
  15. Draw the camshaft sprocket onto the camshaft using the mounting bolts and tighten to 12 ft. lbs. (16 Nm).
  16.  
  17. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
  18.  
  19. Coat the crankshaft and camshaft sprockets with clean engine oil.
  20.  
  21. Install the engine front cover gasket.
  22.  
  23. Install the engine front cover and tighten the bolts to 18 ft. lbs. (25 Nm).
  24.  
  25. Install the water pump.
  26.  
  27. Install the thermostat housing.
  28.  
  29. Install the crankshaft position actuator magnet.
  30.  
  31. Install the camshaft position actuator magnet O-ring seal and magnet.
  32.  
  33. Install the camshaft position actuator magnet bolts and tighten to 89 inch lbs. (10 Nm).
  34.  
  35. Connect the camshaft position actuator magnet electrical connector.
  36.  
  37. Install the engine mount strut bracket and tighten to 18 ft. lbs. (25 Nm).
  38.  
  39. Install the air cleaner assembly.
  40.  
  41. Install the intake manifold cover.
  42.  
  43. Lubricate the new crankshaft front oil seal using clean engine oil.
  44.  
  45. Insert the oil seal into the front cover with the lip facing the engine and seat the seal.
  46.  
  47. Install the crankshaft key into the keyway.
  48.  
  49. Install the crankshaft balancer and tighten the bolt to 52 ft. lbs. (70 Nm), plus an additional 70 degrees.
  50.  
  51. Unlock the flywheel.
  52.  
  53. Install the torque converter covers.
  54.  
  55. Install the oil pan.
  56.  
  57. Raise the frame into the original position.
  58.  
  59. Install and tighten the right and left side frame bolts to 74 ft. lbs. (100 Nm) plus an additional 90 degrees.
  60.  
  61. Install the right engine splash shield.
  62.  
  63. Install the right front tire and wheel.
  64.  
  65. Lower the vehicle.
  66.  
  67. Install the drive belt tensioner and drive belt.
  68.  
  69. Fill the engine with clean oil.
  70.  
  71. Fill and bleed the cooling system.
  72.  
  73. Start the engine and check for proper operation.
  74.  

 
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