Pacifica, 2003-2005

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Evacuate air conditioning system.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Remove the air cleaner.
  12.  
  13. Loosen the water pump pulley bolts.
  14.  
  15. Remove the accessory drive belt and belt tensioner.
  16.  
  17. Remove the power steering pump and set the pump aside.
  18.  
  19. Remove the alternator.
  20.  
  21. Disconnect the air conditioning compressor clutch electrical connector and suction discharge hoses.
  22.  
  23. Remove the dipstick tube.
  24.  
  25. Drain the engine oil.
  26.  
  27. Remove right wheel and inner splash shield.
  28.  
  29. Remove the oil pan.
  30.  
  31. Disconnect the lower radiator hose and the oil cooler hose at the coolant cross over pipe.
  32.  
  33. Separate the power steering lines from the A/C bracket and bracket at the cradle.
  34.  
  35. Separate the air conditioning compressor from the engine and set aside.
  36.  
  37. Remove the crankshaft damper using tool # 8454 and insert # 8450.
  38.  
  39. Remove the coolant cross over pipe fasteners and pipe.
  40.  
  41. Remove the accessible lower timing cover fasteners through the wheel well.
  42.  
  43. Remove Camshaft Position (CMP) sensor from the timing chain cover.
  44.  
  45. Remove the water pump.
  46.  
  47. Support the engine with a floor jack and remove the upper engine mount assembly.
  48.  
  49. Remove the timing chain cover fasteners and cover.
  50.  
  51. Clean the timing cover mating surfaces.
  52.  
  53. Rotate the engine so that the timing marks are aligned.
  54.  
  55. Remove or disconnect the following:

    Camshaft sprocket attaching bolt
     
    Timing chain and camshaft sprocket
     
    Crankshaft sprocket with special tools 8539, 5048-6 and 5048-1
     

  56.  

To install:

Click image to see an enlarged view

Fig. Timing mark alignment-3.8L engines

Timing mark alignment-3.8L engines

  1. Rotate the engine so the timing arrow is at the 12 o-clock position.
  2.  
  3. Lubricate the chain and sprockets with clean oil.
  4.  
  5. Hold the camshaft sprocket and chain and place the chain around the sprocket aligning the plated link with the dot on the sprocket. Position the timing arrow at the 6 o-clock position.
  6.  
  7. Place the chain around the crankshaft sprocket with the plated link lined up with the dot on the sprocket and install the camshaft sprocket.
  8.  
  9. Use a straight edge to check the timing alignment marks.
  10.  
  11. Align the timing chain colored links with the dots on the timing sprockets.
  12.  
  13. Tighten the camshaft sprocket bolt to 40 ft. lbs. (54 Nm).
  14.  
  15. Rotate the crankshaft 2 revolutions and verify the proper timing chain alignment, if not remove the components and reinstall as described above.
    NOTE
    Do not use sealer on cover gasket

  16.  
  17. Position a new gasket on the timing cover. Adhere the new gasket to the chain case cover, making sure that the lower edge of the gasket is 0.020 inch (0.5 mm) beyond the lower edge of the cover.
  18.  
  19. Rotate the crankshaft so that the oil pump drive flats are in the vertical position.
  20.  
  21. Position the oil pump inner rotor so the mating flats are in the same position as the crankshaft drive flats.
    CAUTION
    Make sure the oil pump is engaged on the crankshaft correctly or severe damage may result.

  22.  
  23. Install the timing cover.
  24.  
  25. Install the timing chain cover bolts. Tighten the M8 bolts to 20 ft. lbs. ( 27 Nm) and the M10 bolts to 40 ft. lbs. (54 Nm).

    Click image to see an enlarged view

    Fig. Timing chain cover bolt locations-3.8L engines

    Timing chain cover bolt locations-3.8L engines
  26.  
  27. Install the crankshaft front oil seal.
  28.  
  29. Install the crankshaft damper.
  30.  
  31. Install the coolant cross over pipe.
  32.  
  33. Install the A/C compressor.
  34.  
  35. Position and install the power steering line hold downs at the cradle and A/C bracket.
  36.  
  37. Connect the coolant hoses to the coolant crossover pipe.
  38.  
  39. Install the inner fender splash shield.
  40.  
  41. Install oil pump pick-up tube with a new O-ring. Tighten the bolt to 250 inch lbs. (28 Nm).
  42.  
  43. Install the oil pan.
  44.  
  45. Install the water pump and pulley.
  46.  
  47. Install the CMP sensor.
  48.  
  49. Connect the A/C electrical connector and the suction, discharge hoses.
  50.  
  51. Install the dipstick tube.
  52.  
  53. Install the alternator.
  54.  
  55. Install the power steering pump.
  56.  
  57. Install the idler pulley and drive belt.
  58.  
  59. Install the upper engine.
  60.  
  61. Fill the crankcase with engine oil to the proper level.
  62.  
  63. Fill the cooling system.
  64.  
  65. Evacuate and recharge the A/C system.
  66.  
  67. Check and refill all fluid levels.
  68.  
  69. Connect the negative battery cable.
  70.  

 
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