Infiniti Car 1998-05

Timing Chain Cover, Chain, Sprockets, & Seal 1

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercovers
     
    Right front wheel
     
    Engine side cover and lower the vehicle
     
    Radiator
     
    Intake manifold air duct
     
    Drive belts, water pump pulley, alternator and power steering pump
     
    Vacuum hoses, fuel hoses and wiring harness connectors
     
    Spark plugs
     
    Cylinder head cover and oil separator
     
    Intake manifold supports
     
    Oil filter bracket and the power steering oil pump bracket
     

  10.  
  11. Place the No. 1 piston at Top Dead Center (TDC) on the compression stroke.

    Chain tensioner
     
    Distributor. Do not turn the rotor while the distributor is removed.
     
    Timing chain guide
     
    Camshaft sprockets
     
    Camshafts, camshaft brackets, oil tubes and baffle plate
     
    Starter
     
    Heater hoses and the water hoses from the cylinder head
     
    Knock sensor harness connector
     
    Cylinder head outside bolts
     
    Cylinder head with the intake and exhaust manifolds and raise and support the vehicle safely
     
    Oil pans
     
    Oil strainer and baffle plate
     
    Crankshaft pulley and place a transmission jack under the main bearing beam and raise the engine slightly to take the weight off of the front engine mount
     
    Front engine mount
     
    Timing chain cover. Tap the seal out of the cover with a suitable seal driver.
     
    Timing chain sprocket bolts
     
    Timing chain guides, timing chain and sprockets
     

  12.  

To install:

  1. Be sure all sealing surfaces are clean and prepared for assembly.
  2.  
  3. Install or connect the following:

    Crankshaft sprocket. Position the crankshaft so No. 1 piston is set at TDC (keyway at 12 o'clock, mating mark at 4 o'clock).
     

  4.  
  5. Fit the timing chain to crankshaft sprocket with the gold mating mark on the chain aligned with the mark on the sprocket. (The mating marks for the camshaft sprockets are silver).

    Timing chain guides and hang the chain off the left (front) guide. If necessary, secure the chain so it does not disengage from the crankshaft sprocket during assembly.
     
    New seal in the front cover and apply engine oil to the lip of the seal and apply a bead of liquid gasket to the front cover
     
    Oil pump drive spacer and front cover. Torque the bolts evenly to 60 inch lbs. (6.7 Nm) and wipe away any excess liquid gasket.
     
    Front engine mount
     
    Crankshaft pulley and temporarily tighten the bolt to hold the sprocket in place. The timing mark should align with the TDC mark.
     
    Oil strainer, baffle plate and oil pan
     
    Cylinder head, camshafts, oil tubes and baffles. Position the left camshaft key at 12 o'clock and the right camshaft key at 10 o'clock.
     


    Click image to see an enlarged view

    Fig. During disassembly, be sure to align the timing chain and camshaft sprocket mating marks-2.0L engine



    Click image to see an enlarged view

    Fig. Crankshaft sprocket and timing chain alignment marks-2.0L engine

    Camshaft sprockets by lining up the mating marks on the timing chain with the mating marks on the camshaft sprockets. Torque the camshaft bolts to 101-116 ft. lbs. (137-157 Nm) and the crankshaft pulley bolt to 105-112 ft. lbs. (142-152 Nm).
     
    Upper timing chain guide and distributor. Ensure that the rotor is at the 5 o'clock position.
     

  6.  
  7. Before installing the chain tensioner, press the cam stopper down and the push in the sleeve until the hook can be engaged on the pin. When tensioner is bolted in position, the hook will release automatically. Ensure the arrow on the outside faces the front of the engine.

    Oil filter bracket and the power steering pump bracket
     
    Intake manifold supports
     
    Oil separator and the cylinder head cover
     
    Spark plugs
     
    Vacuum hoses, fuel hoses, and wiring harness connectors
     
    Alternator and power steering pump
     
    Water pump pulley
     
    Drive belts
     
    Radiator
     
    Engine undercovers
     
    Right front wheel
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the cooling system.
  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Engine under covers
     
    Right front wheel
     
    Engine side cover and lower the vehicle
     
    Radiator
     
    Intake manifold air duct
     
    Drive belts, water pump pulley, alternator and power steering pump
     
    Vacuum hoses, fuel hoses and wiring harness connectors
     
    Spark plugs
     
    Cylinder head cover and oil separator
     
    Intake manifold supports
     
    Oil filter bracket and the power steering oil pump bracket
     

  10.  
  11. Place the No. 1 piston at Top Dead Center (TDC) on the compression stroke.

    Chain tensioner
     
    Distributor. Do not turn the rotor while the distributor is removed
     
    Timing chain guide
     
    Camshaft sprockets
     
    Camshafts, camshaft brackets, oil tubes and baffle plate
     
    Starter
     
    Heater hoses and the water hoses from the cylinder head
     
    Knock sensor harness connector
     
    Cylinder head outside bolts
     
    Cylinder head with the intake and exhaust manifolds and raise and support the vehicle safely
     
    Oil pans
     
    Oil strainer and baffle plate
     
    Crankshaft pulley and place a transmission jack under the main bearing beam and raise the engine slightly to take the weight off of the front engine mount
     
    Front engine mount
     
    Timing chain cover. Tap the seal out of the cover with a suitable seal driver
     
    Timing chain sprocket bolts
     
    Timing chain guides, timing chain and sprockets
     

  12.  

To install:

  1. Be sure all sealing surfaces are clean and prepared for assembly.
  2.  
  3. Install or connect the following:

    Crankshaft sprocket. Position the crankshaft so No. 1 piston is set at TDC (keyway at 12 o'clock, mating mark at 4 o'clock)
     

  4.  
  5. Fit the timing chain to crankshaft sprocket with the gold mating mark on the chain aligned with the mark on the sprocket. (The mating marks for the camshaft sprockets are silver).

    Timing chain guides and hang the chain off the left (front) guide. If necessary, secure the chain so it does not disengage from the crankshaft sprocket during assembly
     
    New seal in the front cover and apply engine oil to the lip of the seal and apply a bead of liquid gasket to the front cover
     
    Oil pump drive spacer and front cover. Torque the bolts evenly to 60 inch lbs. (6.7 Nm) and wipe away any excess liquid gasket
     
    Front engine mount
     
    Crankshaft pulley and temporarily tighten the bolt to hold the sprocket in place. The timing mark should align with the TDC mark
     
    Oil strainer, baffle plate and oil pan
     
    Cylinder head, camshafts, oil tubes and baffles. Position the left camshaft key at 12 o'clock and the right camshaft key at 10 o'clock

    Click image to see an enlarged view

    Fig. During disassembly, be sure to align the timing chain and camshaft sprocket mating marks-2.0L engine



    Click image to see an enlarged view

    Fig. Crankshaft sprocket and timing chain alignment marks-2.0L engine

     
    Camshaft sprockets by lining up the mating marks on the timing chain with the mating marks on the camshaft sprockets. Torque the camshaft bolts to 101-116 ft. lbs. (137-157 Nm) and the crankshaft pulley bolt to 105-112 ft. lbs. (142-152 Nm)
     
    Upper timing chain guide and distributor. Ensure that the rotor is at the 5 o'clock position
     

  6.  
  7. Before installing the chain tensioner, press the cam stopper down and the push in the sleeve until the hook can be engaged on the pin. When tensioner is bolted in position, the hook will release automatically. Ensure the arrow on the outside faces the front of the engine.

    Oil filter bracket and the power steering pump bracket
     
    Intake manifold supports
     
    Oil separator and the cylinder head cover
     
    Spark plugs
     
    Vacuum hoses, fuel hoses, and wiring harness connectors
     
    Alternator and power steering pump
     
    Water pump pulley
     
    Drive belts
     
    Radiator
     
    Engine under covers
     
    Right front wheel
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the cooling system.
  10.  
  11. Start the vehicle, check for leaks and repair if necessary.
  12.  

3.0L Engine


Click image to see an enlarged view

Fig. Timing chain tensioner and guide locations-3.0L 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. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Left side ornament cover
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and the harness connections
     
    Evaporative emissions (EVAP) canister purge hoses
     
    Water hoses from the cylinder head and intake manifold
     
    Ignition coils from the spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Intake manifold collector supports and the collector
     
    Bolts that secure the fuel tube and the fuel tube from the vehicle
     
    Bolts that secure the intake manifold to the engine block and the manifold. Loosen the bolts in the reverse sequence of the tightening procedure.
     
    Left-hand and right-hand rocker covers from the cylinder head
     
    Engine undercovers
     
    Right front wheel and the engine side covers
     
    Drive belts and the idler pulley
     
    Power steering oil pump belt and the power steering oil pump assembly
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
     

  10.  
  11. Set the No. 1 piston to Top Dead Center (TDC) of compression stroke by rotating the crankshaft.

    Ring gear cover access plate
     

  12.  
  13. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate.
  14.  


NOTE
Use care not to damage the ring gear teeth.



Crankshaft pulley using a suitable puller
 
Air conditioning compressor and bracket
 
Front exhaust pipe and its support
 

  1. Hang the engine at the right and left side engine slingers with a suitable hoist.
  2.  
  3. Support the transaxle with jack.

    Right side engine mount and bracket
     
    Center crossmember assembly
     
    Steel oil pan and the oil strainer
     
    Aluminum oil pan
     
    Water pump cover
     
    Front timing chain case bolts in the proper sequence
     



    Click image to see an enlarged view

    Fig. Front timing chain case bolt loosening sequence-3.0L engine



    Timing chain case cover using the seal cutter being careful not to damage the sealing surfaces
     
    Internal timing chain guide and the upper chain guide
     
    Timing chain tensioner and slack side chain guide
     
    Left and right intake camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
     
    Lower timing chain assembly. Be sure to note the aligning marks of the chain before removal.
     

  4.  
  5. Insert a suitable stopper pin for the left and right camshaft tensioners.

    Left and right exhaust camshaft sprocket bolts. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
     
    Upper timing chain assembly. Be sure to note the aligning marks of the chain before removal.
     
    Lower timing chain guide
     
    Crankshaft sprocket
     
    All traces of liquid gasket from the front timing chain case and from the water pump
     

  6.  
  7. Inspect the timing chain for excessive wear or damage and replace if necessary.
  8.  

To install:



Click image to see an enlarged view

Fig. Identification of the intake and exhaust camshaft sprockets-3.0L engine



Click image to see an enlarged view

Fig. Upper timing chain alignment marks-3.0L engine



Click image to see an enlarged view

Fig. Lower timing chain alignment marks-3.0L engine



Click image to see an enlarged view

Fig. Application of liquid gasket to the front timing case-3.0L engine

  1. Install or connect the following:

    Crankshaft sprocket with the mating mark facing out
     

  2.  
  3. Position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head

    Lower timing chain guide. The front mark on the guide should face upwards.
     

  4.  
  5. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
  6.  
  7. Put the exhaust camshaft sprockets onto the dowel pin and torque the mounting bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.

    Timing chains and sprockets to the intake camshafts. Be sure to align the timing chain and sprocket mating marks.
     

  8.  
  9. Remove the left and right camshaft tensioner stopper pins.
  10.  
  11. Align the mating mark on the crankshaft with the matchmark (gold link) on the lower timing chain.

    Lower timing chain to the water pump sprocket
     

  12.  
  13. Working counterclockwise, install the lower timing chain camshaft sprockets. Be sure to align the sprocket marks with the blue links of the timing chain during installation.

    Intake sprocket bolts. Torque the bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.
     
    Internal timing chain guide, upper timing chain guide, lower timing chain tensioner and slack side timing chain guide
     
    Torque the tensioner mounting bolt to 75-96 inch lbs. (8-11 Nm) and the guide bolts to 108-168 inch lbs. (13-19 Nm)
     

  14.  
  15. Apply a 0.102-0.142 in. (3-4mm) continuous bead of liquid gasket to all necessary areas on the front timing cover.

    Timing cover evenly and gently. Be sure to align the dowel pin holes.
     

  16.  
  17. Torque the mounting bolts in sequence as follows:
    1. Bolts No. 1 and 2: 19-23 ft. lbs. (26-31 Nm).
    2.  
    3. Bolts No. 3 to 20: 105-121 inch lbs. (12-14 Nm).
    4.  

  18.  


NOTE
Leave the bolts unattended for 30 minutes or more after tightening. This will allow the liquid gasket to cure sufficiently.



Click image to see an enlarged view

Fig. Front timing chain case bolt tightening sequence-3.0L engine

  1. Apply a 0.091-0.130 in. (2-3mm) continuous bead of liquid gasket to the water pump cover and install the cover. Torque the bolts to 84-108 inch lbs. (10-13 Nm).
  2.  
  3. Apply a 0.12 in. (3mm) continuous bead of liquid gasket to the rocker covers and install the covers. Torque the mounting bolts in sequence as follows:
    1. Bolts No. 1 to 10: 9-26 inch lbs. (1-3 Nm).
    2.  
    3. Bolts No. 1 to 10: 52-69 inch lbs. (6-8 Nm).
    4.  

  4.  
  5. Apply sealant to the front and rear seal of the oil pan.
  6.  
  7. Apply a 0.177-0.217 in. (4.5-5.5mm) continuous bead of liquid gasket to the upper oil pan mating surface and install the oil pan. Torque the bolts in sequence to 12-14 ft. lbs. (16-19 Nm).
  8.  
  9. Install or connect the following:

    Transaxle bolts that secure the oil pan
     
    Oil pan strainer. Torque the bolts to 12-14 ft. lbs. (16-19 Nm).
     

  10.  
  11. Apply a 0.177-0.217 in. (5-6mm) continuous bead of liquid gasket to the lower oil pan mating surface and install the oil pan. Torque the bolts in sequence to 57-66 inch lbs. (6-8 Nm)

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     

  12.  
  13. Remove the engine slinger assembly.

    Front exhaust pipe and its support
     
    A/C compressor and bracket
     
    Crankshaft pulley to the crankshaft and the mounting bolt. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another.
     
    Ring gear cover plate
     
    CMP sensor (PHASE) and CKP sensors (REF)/(POS)
     
    Power steering pump assembly
     
    Drive belts and the idler pulley
     
    Right front wheel
     
    Engine undercovers
     

  14.  
  15. Install the intake manifold using new gaskets. Torque the bolts in sequence and in 2 stages as follows:
    1. 44-86 inch lbs. (5-10 Nm).
    2.  
    3. 16-18 ft. lbs. (22-25 Nm).
    4.  

  16.  
  17. Using new insulators, install the fuel tube assembly. Torque the bolts to 15-20 ft. lbs. (21-26 Nm).
  18.  
  19. Install or connect the following:

    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector. Torque the bolts to 16-18 ft. lbs. (22-25 Nm).
     
    Intake manifold collector support brackets
     
    EGR tube using new gaskets. Torque the bolts to 15-20 ft. lbs. (21-26 Nm) in 2 progressive steps.
     
    Ignition coils. Torque the bolts to 27-33 inch lbs. (3-4 Nm).
     
    Rocker cover ornament on the left side
     
    Water hoses to the cylinder head and intake manifold
     
    EVAP canister purge hoses
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  20.  
  21. Fill the engine with clean oil.
  22.  
  23. Fill and bleed the cooling system.
  24.  
  25. Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  26.  



Click image to see an enlarged view

Fig. Timing chain tensioner and guide locations-3.0L engine

  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. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Left side ornament cover
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and the harness connections
     
    Evaporative emissions (EVAP) canister purge hoses
     
    Water hoses from the cylinder head and intake manifold
     
    Ignition coils from the spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Intake manifold collector supports and the collector
     
    Bolts that secure the fuel tube and the fuel tube from the vehicle
     
    Bolts that secure the intake manifold to the engine block and the manifold. Loosen the bolts in the reverse sequence of the tightening procedure.
     
    Left-hand and right-hand rocker covers from the cylinder head
     
    Engine undercovers
     
    Right front wheel and the engine side covers
     
    Drive belts and the idler pulley
     
    Power steering oil pump belt and the power steering oil pump assembly
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
     

  10.  
  11. Set the No. 1 piston to Top Dead Center (TDC) of compression stroke by rotating the crankshaft.

    Ring gear cover access plate
     

  12.  
  13. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate.
    NOTE
    Use care not to damage the ring gear teeth.



    Crankshaft pulley using a suitable puller
     
    Air conditioning compressor and bracket
     
    Front exhaust pipe and its support
     

  14.  
  15. Hang the engine at the right and left side engine slingers with a suitable hoist.
  16.  
  17. Support the transaxle with jack.

    Right side engine mount and bracket
     
    Center crossmember assembly
     
    Steel oil pan and the oil strainer
     
    Aluminum oil pan
     
    Water pump cover
     
    Front timing chain case bolts in the proper sequence

    Click image to see an enlarged view

    Fig. Front timing chain case bolt loosening sequence-3.0L engine

     



    Timing chain case cover using the seal cutter being careful not to damage the sealing surfaces
     
    Internal timing chain guide and the upper chain guide
     
    Timing chain tensioner and slack side chain guide
     
    Left and right intake camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts
     
    Lower timing chain assembly. Be sure to note the aligning marks of the chain before removal
     

  18.  
  19. Insert a suitable stopper pin for the left and right camshaft tensioners.

    Left and right exhaust camshaft sprocket bolts. Be sure to hold the flats of the camshafts while removing the sprocket bolts
     
    Upper timing chain assembly. Be sure to note the aligning marks of the chain before removal
     
    Lower timing chain guide
     
    Crankshaft sprocket
     
    All traces of liquid gasket from the front timing chain case and from the water pump
     

  20.  
  21. Inspect the timing chain for excessive wear or damage and replace if necessary.
  22.  

To install:

Click image to see an enlarged view

Fig. Identification of the intake and exhaust camshaft sprockets-3.0L engine



Click image to see an enlarged view

Fig. Upper timing chain alignment marks-3.0L engine



Click image to see an enlarged view

Fig. Lower timing chain alignment marks-3.0L engine



Click image to see an enlarged view

Fig. Application of liquid gasket to the front timing case-3.0L engine

  1. Install or connect the following:

    Crankshaft sprocket with the mating mark facing out
     

  2.  
  3. Position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head

    Lower timing chain guide. The front mark on the guide should face upwards
     

  4.  
  5. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
  6.  
  7. Put the exhaust camshaft sprockets onto the dowel pin and torque the mounting bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.

    Timing chains and sprockets to the intake camshafts. Be sure to align the timing chain and sprocket mating marks
     

  8.  
  9. Remove the left and right camshaft tensioner stopper pins.
  10.  
  11. Align the mating mark on the crankshaft with the matchmark (gold link) on the lower timing chain.

    Lower timing chain to the water pump sprocket
     

  12.  
  13. Working counterclockwise, install the lower timing chain camshaft sprockets. Be sure to align the sprocket marks with the blue links of the timing chain during installation.

    Intake sprocket bolts. Torque the bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts
     
    Internal timing chain guide, upper timing chain guide, lower timing chain tensioner and slack side timing chain guide
     
    Torque the tensioner mounting bolt to 75-96 inch lbs. (8-11 Nm) and the guide bolts to 108-168 inch lbs. (13-19 Nm)
     

  14.  
  15. Apply a 0.102-0.142 in. (3-4mm) continuous bead of liquid gasket to all necessary areas on the front timing cover.

    Timing cover evenly and gently. Be sure to align the dowel pin holes
     

  16.  
  17. Torque the mounting bolts in sequence as follows:
    1. Bolts No. 1 and 2: 19-23 ft. lbs. (26-31 Nm).
    2.  
    3. Bolts No. 3 to 20: 105-121 inch lbs. (12-14 Nm).
      NOTE
      Leave the bolts unattended for 30 minutes or more after tightening. This will allow the liquid gasket to cure sufficiently.



      Click image to see an enlarged view

      Fig. Front timing chain case bolt tightening sequence-3.0L engine

    4.  

  18.  
  19. Apply a 0.091-0.130 in. (2-3mm) continuous bead of liquid gasket to the water pump cover and install the cover. Torque the bolts to 84-108 inch lbs. (10-13 Nm).
  20.  
  21. Apply a 0.12 in. (3mm) continuous bead of liquid gasket to the rocker covers and install the covers. Torque the mounting bolts in sequence as follows:
    1. Bolts No. 1 to 10: 9-26 inch lbs. (1-3 Nm).
    2.  
    3. Bolts No. 1 to 10: 52-69 inch lbs. (6-8 Nm).
    4.  

  22.  
  23. Apply sealant to the front and rear seal of the oil pan.
  24.  
  25. Apply a 0.177-0.217 in. (4.5-5.5mm) continuous bead of liquid gasket to the upper oil pan mating surface and install the oil pan. Torque the bolts in sequence to 12-14 ft. lbs. (16-19 Nm).
  26.  
  27. Install or connect the following:

    Transaxle bolts that secure the oil pan
     
    Oil pan strainer. Torque the bolts to 12-14 ft. lbs. (16-19 Nm)
     

  28.  
  29. Apply a 0.177-0.217 in. (5-6mm) continuous bead of liquid gasket to the lower oil pan mating surface and install the oil pan. Torque the bolts in sequence to 57-66 inch lbs. (6-8 Nm)

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     

  30.  
  31. Remove the engine slinger assembly.

    Front exhaust pipe and its support
     
    A/C compressor and bracket
     
    Crankshaft pulley to the crankshaft and the mounting bolt. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another
     
    Ring gear cover plate
     
    CMP sensor (PHASE) and CKP sensors (REF)/(POS)
     
    Power steering pump assembly
     
    Drive belts and the idler pulley
     
    Right front wheel
     
    Engine undercovers
     

  32.  
  33. Install the intake manifold using new gaskets. Torque the bolts in sequence and in 2 stages as follows:
    1. 44-86 inch lbs. (5-10 Nm).
    2.  
    3. 16-18 ft. lbs. (22-25 Nm).
    4.  

  34.  
  35. Using new insulators, install the fuel tube assembly. Torque the bolts to 15-20 ft. lbs. (21-26 Nm).
  36.  
  37. Install or connect the following:

    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector. Torque the bolts to 16-18 ft. lbs. (22-25 Nm)
     
    Intake manifold collector support brackets
     
    EGR tube using new gaskets. Torque the bolts to 15-20 ft. lbs. (21-26 Nm) in 2 progressive steps
     
    Ignition coils. Torque the bolts to 27-33 inch lbs. (3-4 Nm)
     
    Rocker cover ornament on the left side
     
    Water hoses to the cylinder head and intake manifold
     
    EVAP canister purge hoses
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  38.  
  39. Fill the engine with clean oil.
  40.  
  41. Fill and bleed the cooling system.
  42.  
  43. Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  44.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Right and left side rocker covers
     
    Cooling fan and radiator
     
    A/C compressor from bracket and position side with the lines attached
     
    A/C compressor bracket
     
    Power steering pump from its bracket and position aside with the lines attached
     
    Power steering pump bracket
     
    Water bypass hose and cooling fan bracket from the front timing chain case
     
    Lower and upper oil pans
     
    Right and left side intake valve timing control covers. Loosen the bolts in the reverse of the tightening sequence. Use a seal cutter to cut the gasket.
     

  8.  
  9. Set the No. 1 piston to Top Dead Center (TDC) on its compression stroke. Align the timing mark (grooved line) on the crankshaft pulley with the timing indicator on the front cover.
  10.  
  11. Make sure the intake and exhaust cam nose for the No. 1 cylinder is positioned as shown in the illustration. If not, turn the crankshaft on revolution (360°) and align.
  12.  
  13. Remove or disconnect the following:

    Crankshaft pulley using a suitable puller
     
    Front timing chain case. Loosen the bolts in the reverse of the torque sequence.
     

  14.  


    Click image to see an enlarged view

    Fig. Intake valve timing control cover tightening sequence-3.5L engine



    Click image to see an enlarged view

    Fig. Proper orientation of the intake and exhaust cams-3.5L engine



    Click image to see an enlarged view

    Fig. Front timing chain case torque sequence (loosen in reverse order)-3.5L engine



WARNING
Do not use a screwdriver to pry the case off!



Timing chain case. Insert the proper tool into the notch at the top of the case as shown. Pry the case off by levering the tool as shown. Use a seat cutter to cut the liquid gasket.
 


Click image to see an enlarged view

Fig. Front timing chain case removal, using a suitable tool-3.5L engine

Water pump cover and chain tensioner cover from the case
 
Front oil seal from the case using a suitable prytool, being careful not the damage the case
 
Internal chain guide, timing chain tensioner and slack guide. Remove the upper chain tensioner by pressing the tensioner in and inserting a 0.098 inch (2.5mm) diameter pin in the pin hole. Once secured remove the bolts and the tensioner.
 


WARNING
After the timing chain is removed, do NOT turn the crankshaft and camshaft separately, or the valve will strike the pistons.

  1. Remove the timing chain and camshaft sprocket, as follows:
    1. Attach a suitable stopper pin to the right and left camshaft chain tensioners (for secondary timing chains).
    2.  
    3. Hold the hex part of the camshaft secure with a wrench, then remove the camshaft sprocket mounting bolts.
    4.  
    5. Remove the primary and secondary timing chains with the camshaft sprockets.
    6.  

  2.  
  3. Remove or disconnect the following:

    Tension guide and crankshaft sprocket
     
    Rear timing chain case. Use the reverse of the tightening sequence, then use a seal cutter to separate the gasket.
     

  4.  


    Click image to see an enlarged view

    Fig. Rear timing chain case torque sequence (loosen in reverse order)-3.5L engines


To install:

  1. Install the rear timing chain case as follows:
    1. Install new O-rings onto the cylinder block and head.
    2.  
    3. Apply suitable RTV sealant to the back side of the rear timing chain case as shown in the illustration.
    4.  


      Click image to see an enlarged view

      Fig. Rear timing chain case sealant application-3.5L engines

    5. Install the rear case and tighten the bolts, in sequence, to 9-10 ft. lbs. (11.7-13.7 Nm). There are 2 bolts lengths: Bolts 1, 2, 3, 6-10 are 0.79 in. (20mm) long and the other bolts are 0.63 in. (16mm) long.
    6.  

  2.  
  3. Set the No. 1 piston to Top Dead Center (TDC) on its compression stroke.
  4.  
  5. Install the crankshaft sprocket, making sure the mating marks on the sprocket face the front of the engine.
  6.  
  7. Push the plunger of the secondary chain tensioner and keep it pressed in with a stopper pin.
  8.  
  9. Install the secondary timing chains and camshaft sprockets, as follows:
    1. Align the matchmarks on the secondary timing chain (gold link) with the stamped marks on the intake and exhaust sprockets, then install them.
    2.  

  10.  


NOTE
Matchmarks for the intake sprocket are on the back of the secondary sprocket. There are 2 kinds of marks, the right bank uses round marks and the left bank uses oval marks.

  1. Align the dowel pin and pin hole on the camshaft with the groove and dowel pin on the sprocket, then install them.
  2.  


    Click image to see an enlarged view

    Fig. Camshaft sprocket alignment, right side bank shown-3.5L engine

  3. On the intake side, align the pin hold on the small diameter side of the camshaft front end with the dowel pin on the on the back side of the camshaft sprocket, and install them.
  4.  
  5. On the exhaust side, align the dowel pin on the camshaft front end with the pin groove on the camshaft sprocket, then install them.
  6.  
  7. Tighten the camshaft sprocket bolts hand-tight to prevent the dowel pins from dislocating.
  8.  

  1. Install the primary timing chain, as follows:
    1. Install the primary chain so the punched mating mark on the cam sprocket is aligned with the yellow link on the timing chain, while the notched mating mark on the crankshaft sprocket is aligned with the orange one on the timing chain.
    2.  


      Click image to see an enlarged view

      Fig. Proper alignment for the primary timing chain-3.5L engine

    3. Use a wrench on the hex portion of the camshaft to secure it in place, tighten the camshaft sprocket mounting bolts to 73-78 ft. lbs. (98-108 Nm).
    4.  
    5. Remove the stopper pins from secondary chain tensioners.
    6.  

  2.  
  3. Install the internal chain guide, timing chain tensioner, tension guide and slack guide. Do not overtighten the slack guide mounting bolts. It-s normal to have a gap under the bolt seats when the mounting bolts are properly tightened to 10-13 ft. lbs. (14-18 Nm).
  4.  
  5. Recheck that all matchmarks are still aligned.
  6.  
  7. Install or connect the following:

    New O-rings on the rear timing chain case
     
    New front oil seal in to the timing chain cover
     
    Water pump and chain tensioner covers to the front cover
     
    Suitable liquid gasket to the back side of the timing chain case
     


    Click image to see an enlarged view

    Fig. Apply proper sealant as shown on the back side of the front timing chain case-3.5L engine

    Dowel pin on the rear timing chain case into the dowel pin hold on the front chain case
     
    Front timing chain case bolts, in sequence. Tighten the M6 bolts to 9-10 ft. lbs. (11.7-13.7 Nm) and the M8 bolts to 19-23 ft. lbs. (25-31 Nm).
     
    Right and left intake valve timing control cover
     
    Crankshaft pulley to the crankshaft and the mounting bolt. Torque the mounting bolt to 29-36 ft. lbs. (39-49 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another.
     

  8.  
  9. Installation of the remaining components is the reverse of the removal procedure.
  10.  
  11. Fill the engine with clean oil.
  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Start the engine and check for proper operation.
  16.  

 
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