SRX 2004-2005

Timing Chain Cover & Seal

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Removal & Installation



3.6L Engine

NOTE
3 timing chains are used. The right side secondary chain is on the outside of the primary crankshaft sprocket chain and the left secondary chain is on the inside.

  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
     
    Engine appearance cover
     
    Camshaft covers
     
    Intake manifold
     
    Spark plugs
     
    Radiator hoses
     
    Accessory drive belts
     
    Thermostat housing
     
    A/C compressor and power steering belt tensioners
     
    Alternator
     
    Starter
     

  8.  
  9. Without disconnecting the lines, remove and reposition the power steering reservoir.
  10.  
  11. Remove or disconnect the following:

    Power steering pump pulley
     
    Install flywheel locking tool EN-46106 in the starter mounting holes
     
    Crankshaft damper bolt
     
    Using a gear puller, remove the crankshaft damper
     

  12.  
  13. To remove the front seal only, pry the seal out of the front cover opening.
  14.  
  15. Remove or disconnect the following:

    4 Camshaft Position (CMP) sensors
     
    4 CMP actuator solenoids
     
    Water pump pulley
     
    Front cover bolts, cover and gasket
     

  16.  
  17. Ensure the engine is placed in the Stage 2 timing drive chain alignment position as shown.

    Click image to see an enlarged view

    Fig. Stage 2 timing drive chain alignment position-3.6L engine

  18.  
  19. Remove or disconnect the following:
    NOTE
    The lower primary drive chain guide is not serviceable. If the guide needs to be replaced, the guide and oil pump must be replaced as an assembly.



    Right side secondary drive chain tensioners, guides and shoes
     
    Right secondary drive chain
     
    Primary drive chain tensioner and upper guide
     
    Primary drive chain
     
    Right side secondary drive chain idler sprockets
     
    Left side secondary drive chain tensioners, guides and shoes
     
    Left side secondary drive chain idler sprockets
     
    Left secondary drive chain
     

  20.  
  21. If necessary, remove the crankshaft sprocket.
    NOTE
    There are 4 camshaft position actuator sprockets used. Left and right exhaust and left and right intake camshafts.

  22.  
  23. If the camshafts are to be removed, place an open end wrench on the appropriate camshaft hex location and hold the camshaft, while the removing the camshaft position actuator sprocket bolt and sprocket.
  24.  
  25. If the front seal was not removed earlier, pry the seal out of the front cover opening.
  26.  

To install:

  1. Clean all the gasket mating surfaces.
  2.  
  3. If the camshafts were removed, install the camshafts using the procedure described under Camshafts.
  4.  
  5. Install the camshaft position actuator sprockets and tighten the bolts to 43 ft. lbs. (58 Nm).
  6.  
  7. If the front cover was removed, use a seal installer and install a new front seal into the front cover opening.
  8.  
  9. If removed, install the crankshaft sprocket with the timing mark out and placed in the Stage 1 timing drive position.

    Click image to see an enlarged view

    Fig. Stage 1 timing drive chain alignment position-3.6L engine

  10.  
  11. Install camshaft holding tools EN-46105 on the camshaft rear flats to hold them in position.
  12.  
  13. Install the left side secondary drive chain idler sprockets with the part number outs and the larger sprocket on the outside. Tighten the bolt to 48 ft. lbs. (65 Nm).
  14.  
  15. Install the left secondary timing chain on the inner idler sprocket with the bright plate chain drive link aligned with the hole in the outer sprocket as shown.
  16.  
  17. Place the timing chain around the camshaft sprockets and ensure there are 7 links between the bright links as shown.
  18.  
  19. There will be 18 darkened links between the left camshaft intermediate drive chain idler bright plated secondary camshaft drive chain link and each left camshaft position actuator sprocket bright plated secondary camshaft drive chain link.

    Click image to see an enlarged view

    Fig. Aligning left secondary timing chain to lower idler sprocket-3.6L engine



    Click image to see an enlarged view

    Fig. Aligning left secondary timing chain to camshaft sprockets-3.6L engine

  20.  
  21. Ensure that the correct tensioner is installed in the correct positions as shown.

    Click image to see an enlarged view

    Fig. Identifying timing chain tensioners-3.6L engine

  22.  
  23. Using tensioner tool J-45027 reset the left tensioner plunger.
  24.  
  25. Install the plunger in the tensioner body and lock it in place with a paper clip.
  26.  
  27. Release the pressure on the tensioner and ensure it remains compressed.
  28.  
  29. Install a new gasket on the tensioner, install the tensioner and tighten the bolts to 17 ft. lbs. (23 Nm).
  30.  
  31. Install the left side chain guide and chain shoe and tighten the bolts to 17 ft. lbs. (23 Nm).
  32.  
  33. Install the right side secondary drive chain idler sprockets with the part number outs and the larger sprocket on the outside. Tighten the bolt to 48 ft. lbs. (65 Nm).
  34.  
  35. Place the primary timing chain around the camshaft idler sprockets and crankshaft sprocket with the links and timing marks aligned as shown.

    Click image to see an enlarged view

    Fig. Aligning primary timing chain to camshaft idler and crankshaft sprockets-3.6L engine

  36.  
  37. Using tensioner tool J-45027 reset the primary tensioner plunger.
  38.  
  39. Install the plunger in the tensioner body and lock it in place with a paper clip.
  40.  
  41. Release the pressure on the tensioner and ensure it remains compressed.
  42.  
  43. Install a new gasket on the tensioner, install the tensioner and tighten the bolts to 44 inch lbs. (5 Nm) and then a final pass of 17 ft. lbs. (23 Nm).
  44.  
  45. Release the tension on the primary tensioner, and ensure the primary and left side timing chains are in the Stage 1 position.
  46.  
  47. Remove the camshaft holding tool from the left camshafts.
  48.  
  49. Rotate the crankshaft sprocket clockwise from the Stage 1 to the Stage 2 position. The rotation is approximately 15 degrees.
  50.  
  51. Install the right secondary timing chain on the outer idler sprocket with the bright plate chain drive link aligned with the hole in the inner sprocket as shown.
  52.  
  53. Place the timing chain around the camshaft sprockets and ensure there are 7 links between the bright links as shown.
  54.  
  55. There will be 18 darkened links between the right camshaft intermediate drive chain idler bright plated secondary camshaft drive chain link and each right camshaft position actuator sprocket bright plated secondary camshaft drive chain link.

    Click image to see an enlarged view

    Fig. Aligning right secondary timing chain to lower idler sprocket-3.6L engine



    Click image to see an enlarged view

    Fig. Aligning right secondary timing chain to camshaft sprockets-3.6L engine

  56.  
  57. Using tensioner tool J-45027 reset the right tensioner plunger.
  58.  
  59. Install the plunger in the tensioner body and lock it in place with a paper clip.
  60.  
  61. Release the pressure on the tensioner and ensure it remains compressed.
  62.  
  63. Install a new gasket on the tensioner, install the tensioner and tighten the bolts to 17 ft. lbs. (23 Nm).
  64.  
  65. Install the right side chain guide and chain shoe and tighten the bolts to 17 ft. lbs. (23 Nm).
  66.  
  67. Verify the timing chains are aligned in the Stage 2 timing drive chain alignment position as shown.
  68.  
  69. Install a new front cover-to-cylinder block seal.
  70.  
  71. Place a bead of RTV sealant onto the front cover as shown.

    Click image to see an enlarged view

    Fig. Front cover sealant application areas-3.6L engine

  72.  
  73. Install the front cover and tighten the bolts to 17 ft. lbs. (23 Nm).
  74.  
  75. Install or connect the following:
    NOTE
    Do not lubricate the front seal bore. The damper is installed into a dry bore.



    4 CMP sensors and tighten to 89 inch lbs. (10 Nm).
     
    4 CMP actuator solenoids tighten to 89 inch lbs. (10 Nm).
     
    Water pump pulley
     
    Install flywheel locking tool EN-46106 in the starter mounting holes
     



    Press in the crankshaft damper
     
    Tighten the damper bolt to 74 ft. lbs. (100 Nm), plus an additional 150°.
     
    Power steering pump pulley
     
    Power steering reservoir
     
    Starter
     
    Alternator
     
    A/C compressor and power steering belt tensioners
     
    Thermostat housing
     
    Accessory drive belts
     
    Radiator hoses
     
    Spark plugs
     
    Intake manifold
     
    Camshaft covers
     
    Engine appearance cover
     
    Negative battery cable
     

  76.  
  77. Fill the cooling system to the correct level.
  78.  
  79. Fill the engine with oil to the correct level.
  80.  
  81. Start the engine and verify proper operation.
  82.  


NOTE
3 timing chains are used. The right side secondary chain is on the outside of the primary crankshaft sprocket chain and the left secondary chain is on the inside.

  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
     
    Engine appearance cover
     
    Camshaft covers
     
    Intake manifold
     
    Spark plugs
     
    Radiator hoses
     
    Accessory drive belts
     
    Thermostat housing
     
    A/C compressor and power steering belt tensioners
     
    Alternator
     
    Starter
     

  8.  
  9. Without disconnecting the lines, remove and reposition the power steering reservoir.
  10.  
  11. Remove or disconnect the following:

    Power steering pump pulley
     
    Install flywheel locking tool EN-46106 in the starter mounting holes
     
    Crankshaft damper bolt
     
    Using a gear puller, remove the crankshaft damper
     

  12.  
  13. To remove the front seal only, pry the seal out of the front cover opening.
  14.  
  15. Remove or disconnect the following:

    4 Camshaft Position (CMP) sensors
     
    4 CMP actuator solenoids
     
    Water pump pulley
     
    Front cover bolts, cover and gasket
     

  16.  
  17. Ensure the engine is placed in the Stage 2 timing drive chain alignment position as shown.

    Click image to see an enlarged view

    Fig. Stage 2 timing drive chain alignment position-3.6L engine

  18.  
  19. Remove or disconnect the following:
    NOTE
    The lower primary drive chain guide is not serviceable. If the guide needs to be replaced, the guide and oil pump must be replaced as an assembly.



    Right side secondary drive chain tensioners, guides and shoes
     
    Right secondary drive chain
     
    Primary drive chain tensioner and upper guide
     
    Primary drive chain
     
    Right side secondary drive chain idler sprockets
     
    Left side secondary drive chain tensioners, guides and shoes
     
    Left side secondary drive chain idler sprockets
     
    Left secondary drive chain
     

  20.  
  21. If necessary, remove the crankshaft sprocket.
    NOTE
    There are 4 camshaft position actuator sprockets used. Left and right exhaust and left and right intake camshafts.

  22.  
  23. If the camshafts are to be removed, place an open end wrench on the appropriate camshaft hex location and hold the camshaft, while the removing the camshaft position actuator sprocket bolt and sprocket.
  24.  
  25. If the front seal was not removed earlier, pry the seal out of the front cover opening.
  26.  

To install:

  1. Clean all the gasket mating surfaces.
  2.  
  3. If the camshafts were removed, install the camshafts using the procedure described under Camshafts.
  4.  
  5. Install the camshaft position actuator sprockets and tighten the bolts to 43 ft. lbs. (58 Nm).
  6.  
  7. If the front cover was removed, use a seal installer and install a new front seal into the front cover opening.
  8.  
  9. If removed, install the crankshaft sprocket with the timing mark out and placed in the Stage 1 timing drive position.

    Click image to see an enlarged view

    Fig. Stage 1 timing drive chain alignment position-3.6L engine

  10.  
  11. Install camshaft holding tools EN-46105 on the camshaft rear flats to hold them in position.
  12.  
  13. Install the left side secondary drive chain idler sprockets with the part number outs and the larger sprocket on the outside. Tighten the bolt to 48 ft. lbs. (65 Nm).
  14.  
  15. Install the left secondary timing chain on the inner idler sprocket with the bright plate chain drive link aligned with the hole in the outer sprocket as shown.
  16.  
  17. Place the timing chain around the camshaft sprockets and ensure there are 7 links between the bright links as shown.
  18.  
  19. There will be 18 darkened links between the left camshaft intermediate drive chain idler bright plated secondary camshaft drive chain link and each left camshaft position actuator sprocket bright plated secondary camshaft drive chain link.

    Click image to see an enlarged view

    Fig. Aligning left secondary timing chain to lower idler sprocket-3.6L engine



    Click image to see an enlarged view

    Fig. Aligning left secondary timing chain to camshaft sprockets-3.6L engine

  20.  
  21. Ensure that the correct tensioner is installed in the correct positions as shown.

    Click image to see an enlarged view

    Fig. Identifying timing chain tensioners-3.6L engine

  22.  
  23. Using tensioner tool J-45027 reset the left tensioner plunger.
  24.  
  25. Install the plunger in the tensioner body and lock it in place with a paper clip.
  26.  
  27. Release the pressure on the tensioner and ensure it remains compressed.
  28.  
  29. Install a new gasket on the tensioner, install the tensioner and tighten the bolts to 17 ft. lbs. (23 Nm).
  30.  
  31. Install the left side chain guide and chain shoe and tighten the bolts to 17 ft. lbs. (23 Nm).
  32.  
  33. Install the right side secondary drive chain idler sprockets with the part number outs and the larger sprocket on the outside. Tighten the bolt to 48 ft. lbs. (65 Nm).
  34.  
  35. Place the primary timing chain around the camshaft idler sprockets and crankshaft sprocket with the links and timing marks aligned as shown.

    Click image to see an enlarged view

    Fig. Aligning primary timing chain to camshaft idler and crankshaft sprockets-3.6L engine

  36.  
  37. Using tensioner tool J-45027 reset the primary tensioner plunger.
  38.  
  39. Install the plunger in the tensioner body and lock it in place with a paper clip.
  40.  
  41. Release the pressure on the tensioner and ensure it remains compressed.
  42.  
  43. Install a new gasket on the tensioner, install the tensioner and tighten the bolts to 44 inch lbs. (5 Nm) and then a final pass of 17 ft. lbs. (23 Nm).
  44.  
  45. Release the tension on the primary tensioner, and ensure the primary and left side timing chains are in the Stage 1 position.
  46.  
  47. Remove the camshaft holding tool from the left camshafts.
  48.  
  49. Rotate the crankshaft sprocket clockwise from the Stage 1 to the Stage 2 position. The rotation is approximately 15 degrees.
  50.  
  51. Install the right secondary timing chain on the outer idler sprocket with the bright plate chain drive link aligned with the hole in the inner sprocket as shown.
  52.  
  53. Place the timing chain around the camshaft sprockets and ensure there are 7 links between the bright links as shown.
  54.  
  55. There will be 18 darkened links between the right camshaft intermediate drive chain idler bright plated secondary camshaft drive chain link and each right camshaft position actuator sprocket bright plated secondary camshaft drive chain link.

    Click image to see an enlarged view

    Fig. Aligning right secondary timing chain to lower idler sprocket-3.6L engine



    Click image to see an enlarged view

    Fig. Aligning right secondary timing chain to camshaft sprockets-3.6L engine

  56.  
  57. Using tensioner tool J-45027 reset the right tensioner plunger.
  58.  
  59. Install the plunger in the tensioner body and lock it in place with a paper clip.
  60.  
  61. Release the pressure on the tensioner and ensure it remains compressed.
  62.  
  63. Install a new gasket on the tensioner, install the tensioner and tighten the bolts to 17 ft. lbs. (23 Nm).
  64.  
  65. Install the right side chain guide and chain shoe and tighten the bolts to 17 ft. lbs. (23 Nm).
  66.  
  67. Verify the timing chains are aligned in the Stage 2 timing drive chain alignment position as shown.
  68.  
  69. Install a new front cover-to-cylinder block seal.
  70.  
  71. Place a bead of RTV sealant onto the front cover as shown.

    Click image to see an enlarged view

    Fig. Front cover sealant application areas-3.6L engine

  72.  
  73. Install the front cover and tighten the bolts to 17 ft. lbs. (23 Nm).
  74.  
  75. Install or connect the following:
    NOTE
    Do not lubricate the front seal bore. The damper is installed into a dry bore.



    4 CMP sensors and tighten to 89 inch lbs. (10 Nm).
     
    4 CMP actuator solenoids tighten to 89 inch lbs. (10 Nm).
     
    Water pump pulley
     
    Install flywheel locking tool EN-46106 in the starter mounting holes
     



    Press in the crankshaft damper
     
    Tighten the damper bolt to 74 ft. lbs. (100 Nm), plus an additional 150°.
     
    Power steering pump pulley
     
    Power steering reservoir
     
    Starter
     
    Alternator
     
    A/C compressor and power steering belt tensioners
     
    Thermostat housing
     
    Accessory drive belts
     
    Radiator hoses
     
    Spark plugs
     
    Intake manifold
     
    Camshaft covers
     
    Engine appearance cover
     
    Negative battery cable
     

  76.  
  77. Fill the cooling system to the correct level.
  78.  
  79. Fill the engine with oil to the correct level.
  80.  
  81. Start the engine and verify proper operation.
  82.  

4.6L Engine

NOTE
3 timing chains are used. The right side secondary chain is on the outside, the left secondary chain is in the middle and the primary chain is on the inside of the camshaft intermediate sprocket.

  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
     
    Radiator hoses
     
    Camshaft covers
     
    Accessory drive belts
     
    Drive belt tensioners
     
    Drive belt idler pulley
     
    Water pump pulley
     
    Fan adapter, if equipped
     
    Starter
     
    Water pump pulley
     

  8.  
  9. Install a flywheel holding tool in the starter mounting holes.
  10.  
  11. Remove or disconnect the following:

    Crankshaft damper bolt
     
    Using a puller, remove the crankshaft damper
     
    Engine front cover and gasket
     
    Oil pump
     

  12.  
  13. Rotate the crankshaft until the primary timing marks are aligned as shown.

    Click image to see an enlarged view

    Fig. Aligning primary timing marks-4.6L engine

  14.  
  15. Remove or disconnect the following:

    Right side Camshaft Position (CMP) sensors
     
    Right side CMP solenoids.
     
    Right side CMP actuator housings
     
    Install camshaft holding tool EN-46328 on the right side camshafts
     
    Right side timing chain tensioner
     

  16.  
  17. Place an open end wrench on the exhaust camshaft hex to hold the camshaft and remove the oil control valve.
  18.  
  19. Slide the right exhaust camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  20.  
  21. Place an open end wrench on the intake camshaft hex to hold the camshaft and remove the oil control valve.
  22.  
  23. Slide the right intake camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  24.  
  25. Remove the timing chain.
  26.  
  27. Remove the timing chain guide and shoe.
  28.  
  29. Remove or disconnect the following:

    Left side Camshaft Position (CMP) sensors
     
    Left side CMP actuator solenoids
     
    Left side CMP actuator housings
     
    Install camshaft holding tool EN-46328 on the left side camshafts
     
    Left side timing chain tensioner
     

  30.  
  31. Place an open end wrench on the exhaust camshaft hex to hold the camshaft and remove the oil control valve.
  32.  
  33. Slide the left exhaust camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  34.  
  35. Place an open end wrench on the intake camshaft hex to hold the camshaft and remove the oil control valve.
  36.  
  37. Slide the left intake camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  38.  
  39. Remove the timing chain.
  40.  
  41. Remove the timing chain guide and shoe.
  42.  
  43. Remove the primary timing chain tensioner.
  44.  
  45. Remove the oil outlet tube.
  46.  
  47. Remove the camshaft intermediate sprocket bolt.
  48.  
  49. Remove the primary timing drive chain guide.
  50.  
  51. Remove the intermediate sprocket, primary drive chain and crankshaft sprocket as an assembly.
  52.  
  53. Pry the front seal from the timing cover.
  54.  

To install:

  1. Clean all the gasket mating surfaces.
  2.  
  3. Using a seal installer, press in a new front crankshaft seal into the front cover.
  4.  
  5. Align the intermediate and crankshaft sprocket timing marks so they are vertical as shown.
  6.  
  7. Install the primary timing chain around the intermediate and crankshaft sprockets,
  8.  
  9. Verify that the no. 1 piston is at TDC and the crankshaft keyway is at about the 5° ATDC position.
  10.  
  11. Install the intermediate/crankshaft sprocket/timing chain assembly onto the crankshaft and camshaft driveshafts.
  12.  
  13. Install the intermediate sprocket bolt and tighten to 44 ft. lbs. (60 Nm).
  14.  
  15. Install the primary drive chain guide and tighten the bolts to 18 ft. lbs. (25 Nm).
  16.  
  17. Holding the primary drive chain tensioner in one hand, rotate the ratchet release lever counterclockwise with the other hand and place a paper clip to hold it.
  18.  
  19. Collapse the tensioner shoe and hold while slowly releasing the ratchet lever to relive tension on the shoe.
  20.  
  21. Install the chain tensioner and tighten the bolt to 18 ft. lbs. (25 Nm).
  22.  
  23. Remove the paper clip and allow the tensioner to load.
  24.  
  25. Install the oil outlet tube and tighten the bolts to 89 inch lbs. (10 Nm).
  26.  
  27. Install the left side drive chain guide and shoe and tighten the bolts to 18 ft. lbs. (25 Nm).
  28.  
  29. Guide the left timing chain through the cylinder head and onto the inner row of the intermediate drive chain sprocket teeth.
  30.  
  31. Install the left camshaft position actuators into the drive chain.
  32.  
  33. Install the camshaft sprockets on the camshafts.
    NOTE
    Ensure the camshaft sprockets notches marked LI or LE engage the proper camshaft pins.

  34.  
  35. Loosely install the actuator oil control valves.
  36.  
  37. Verify that the camshaft sprocket notches and the camshaft pins are 90° perpendicular to each other.

    Click image to see an enlarged view

    Fig. Aligning left camshaft sprocket marks and camshaft pin marks-4.6L engine ; right side similar

  38.  
  39. Install camshaft locking tool J-46328 to the left camshafts.
  40.  
  41. Install the upper drive chain shoe guide bolt and then tighten the upper and lower bolts to 18 ft. lbs. (25 Nm).
  42.  
  43. Holding the left drive chain tensioner in one hand, rotate the ratchet release lever counterclockwise with the other hand and place a paper clip to hold it.
  44.  
  45. Collapse the tensioner shoe and hold while slowly releasing the ratchet lever to relive tension on the shoe.
  46.  
  47. Install the chain tensioner and tighten the bolt to 18 ft. lbs. (25 Nm).
  48.  
  49. Remove the paper clip and allow the tensioner to load.
  50.  
  51. Install the right side drive chain guide and shoe and tighten the bolts to 18 ft. lbs. (25 Nm).
  52.  
  53. Guide the right timing chain through the cylinder head and onto the outer row of the intermediate drive chain sprocket teeth.
  54.  
  55. Install the right camshaft position actuators into the drive chain.
  56.  
  57. Install the camshaft sprockets on the camshafts.
    NOTE
    Ensure the camshaft sprockets notches marked RI or RE engage the proper camshaft pins.

  58.  
  59. Loosely install the actuator oil control valves.
  60.  
  61. Verify that the camshaft sprocket notches and the camshaft pins are 90° perpendicular to each other.
  62.  
  63. Install camshaft locking tool J-46328 to the right camshafts.
  64.  
  65. Install the upper drive chain shoe guide bolt and then tighten the upper and lower bolts to 18 ft. lbs. (25 Nm).
  66.  
  67. Holding the right drive chain tensioner in one hand, rotate the ratchet release lever counterclockwise with the other hand and place a paper clip to hold it.
  68.  
  69. Collapse the tensioner shoe and hold while slowly releasing the ratchet lever to relive tension on the shoe.
  70.  
  71. Install the chain tensioner and tighten the bolt to 18 ft. lbs. (25 Nm).
  72.  
  73. Remove the paper clip and allow the tensioner to load.
  74.  
  75. Ensure the correct alignment of all timing chain marks.
  76.  
  77. Tighten all 4 oil control valves, holding the camshaft flats to prevent camshaft rotation. Tighten the oil control valve bolts to 90 ft. lbs. (120 Nm).
  78.  
  79. Remove the camshaft holding tools.
  80.  
  81. Install a new gasket to the right side camshaft actuator housing, install the housing and tighten the bolts to 89 inch lbs. (10 Nm).
    NOTE
    The camshaft position actuators solenoids must be precisely aligned to the camshaft position actuator oil control valves on the ends of the camshafts. This is done with an alignment pin. Failure to align the solenoids correctly can lead to poor engine performance and component damage.

  82.  
  83. Fabricate an alignment pin using a 15/64 inch drill bit at least 2 inches long.
  84.  
  85. Verify the alignment pin will pass through intake actuator solenoid alignment hole and the control valve alignment hole.
  86.  
  87. Apply a bead of RTV sealant around the actuator solenoid flange.
  88.  
  89. Install the actuator over the oil control valve and insert the alignment pin to align the valve to the solenoid.
  90.  
  91. Tighten the actuator solenoid bolts to 71 inch lbs. (8 Nm).
  92.  
  93. Install a new actuator solenoid plug.
  94.  
  95. Repeat this procedure on the right exhaust actuator solenoid, and both left side actuator solenoids.
  96.  
  97. Install the oil pump.
  98.  
  99. Clean the front cover gasket surface.
  100.  
  101. Place a small amount of sealant to the split line of the upper and lower crankcases and the top edge of the block face.
  102.  
  103. Install a new front cover gasket over the crankcase dowel pins.
  104.  
  105. Install the front cover and hand tighten the bolts.
  106.  
  107. Tighten the front cover bolts in the sequence shown to 106 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Engine front cover bolt tightening sequence-4.6L engine

  108.  
  109. Install the 4 CMP sensors and tighten to 89 inch lbs. (10 Nm).
  110.  
  111. Install the camshaft covers
  112.  
  113. Press the crankshaft damper on.
  114.  
  115. Coat the damper bolt with clean engine oil, install the bolt and tighten to 37 ft. lbs. (50 Nm), plus an additional 120°.
  116.  
  117. Remove the crankshaft holding tool from the starter opening and install the starter.
  118.  
  119. Install the water pump pulley and tighten the bolts to 89 inch lbs. (10 Nm).
  120.  
  121. Install the drive belt idler pulley and tighten to 37 ft. lbs. (50 Nm).
  122.  
  123. Install or connect the following:

    Fan adapter, if equipped
     
    Drive belt tensioners
     
    Accessory drive belts
     
    Radiator hoses
     
    Engine appearance cover
     
    Air outlet duct
     
    Negative battery cable
     

  124.  
  125. Fill the cooling system to the correct level.
  126.  
  127. Fill the engine with oil to the correct level.
  128.  
  129. Start the engine and verify proper operation.
  130.  


NOTE
3 timing chains are used. The right side secondary chain is on the outside, the left secondary chain is in the middle and the primary chain is on the inside of the camshaft intermediate sprocket.

  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
     
    Radiator hoses
     
    Camshaft covers
     
    Accessory drive belts
     
    Drive belt tensioners
     
    Drive belt idler pulley
     
    Water pump pulley
     
    Fan adapter, if equipped
     
    Starter
     
    Water pump pulley
     

  8.  
  9. Install a flywheel holding tool in the starter mounting holes.
  10.  
  11. Remove or disconnect the following:

    Crankshaft damper bolt
     
    Using a puller, remove the crankshaft damper
     
    Engine front cover and gasket
     
    Oil pump
     

  12.  
  13. Rotate the crankshaft until the primary timing marks are aligned as shown.

    Click image to see an enlarged view

    Fig. Aligning primary timing marks-4.6L engine

  14.  
  15. Remove or disconnect the following:

    Right side Camshaft Position (CMP) sensors
     
    Right side CMP solenoids.
     
    Right side CMP actuator housings
     
    Install camshaft holding tool EN-46328 on the right side camshafts
     
    Right side timing chain tensioner
     

  16.  
  17. Place an open end wrench on the exhaust camshaft hex to hold the camshaft and remove the oil control valve.
  18.  
  19. Slide the right exhaust camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  20.  
  21. Place an open end wrench on the intake camshaft hex to hold the camshaft and remove the oil control valve.
  22.  
  23. Slide the right intake camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  24.  
  25. Remove the timing chain.
  26.  
  27. Remove the timing chain guide and shoe.
  28.  
  29. Remove or disconnect the following:

    Left side Camshaft Position (CMP) sensors
     
    Left side CMP actuator solenoids
     
    Left side CMP actuator housings
     
    Install camshaft holding tool EN-46328 on the left side camshafts
     
    Left side timing chain tensioner
     

  30.  
  31. Place an open end wrench on the exhaust camshaft hex to hold the camshaft and remove the oil control valve.
  32.  
  33. Slide the left exhaust camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  34.  
  35. Place an open end wrench on the intake camshaft hex to hold the camshaft and remove the oil control valve.
  36.  
  37. Slide the left intake camshaft position actuator off of the camshaft and remove the secondary timing chain from the actuator.
  38.  
  39. Remove the timing chain.
  40.  
  41. Remove the timing chain guide and shoe.
  42.  
  43. Remove the primary timing chain tensioner.
  44.  
  45. Remove the oil outlet tube.
  46.  
  47. Remove the camshaft intermediate sprocket bolt.
  48.  
  49. Remove the primary timing drive chain guide.
  50.  
  51. Remove the intermediate sprocket, primary drive chain and crankshaft sprocket as an assembly.
  52.  
  53. Pry the front seal from the timing cover.
  54.  

To install:

  1. Clean all the gasket mating surfaces.
  2.  
  3. Using a seal installer, press in a new front crankshaft seal into the front cover.
  4.  
  5. Align the intermediate and crankshaft sprocket timing marks so they are vertical as shown.
  6.  
  7. Install the primary timing chain around the intermediate and crankshaft sprockets,
  8.  
  9. Verify that the no. 1 piston is at TDC and the crankshaft keyway is at about the 5° ATDC position.
  10.  
  11. Install the intermediate/crankshaft sprocket/timing chain assembly onto the crankshaft and camshaft driveshafts.
  12.  
  13. Install the intermediate sprocket bolt and tighten to 44 ft. lbs. (60 Nm).
  14.  
  15. Install the primary drive chain guide and tighten the bolts to 18 ft. lbs. (25 Nm).
  16.  
  17. Holding the primary drive chain tensioner in one hand, rotate the ratchet release lever counterclockwise with the other hand and place a paper clip to hold it.
  18.  
  19. Collapse the tensioner shoe and hold while slowly releasing the ratchet lever to relive tension on the shoe.
  20.  
  21. Install the chain tensioner and tighten the bolt to 18 ft. lbs. (25 Nm).
  22.  
  23. Remove the paper clip and allow the tensioner to load.
  24.  
  25. Install the oil outlet tube and tighten the bolts to 89 inch lbs. (10 Nm).
  26.  
  27. Install the left side drive chain guide and shoe and tighten the bolts to 18 ft. lbs. (25 Nm).
  28.  
  29. Guide the left timing chain through the cylinder head and onto the inner row of the intermediate drive chain sprocket teeth.
  30.  
  31. Install the left camshaft position actuators into the drive chain.
  32.  
  33. Install the camshaft sprockets on the camshafts.
    NOTE
    Ensure the camshaft sprockets notches marked LI or LE engage the proper camshaft pins.

  34.  
  35. Loosely install the actuator oil control valves.
  36.  
  37. Verify that the camshaft sprocket notches and the camshaft pins are 90° perpendicular to each other.

    Click image to see an enlarged view

    Fig. Aligning left camshaft sprocket marks and camshaft pin marks-4.6L engine ; right side similar

  38.  
  39. Install camshaft locking tool J-46328 to the left camshafts.
  40.  
  41. Install the upper drive chain shoe guide bolt and then tighten the upper and lower bolts to 18 ft. lbs. (25 Nm).
  42.  
  43. Holding the left drive chain tensioner in one hand, rotate the ratchet release lever counterclockwise with the other hand and place a paper clip to hold it.
  44.  
  45. Collapse the tensioner shoe and hold while slowly releasing the ratchet lever to relive tension on the shoe.
  46.  
  47. Install the chain tensioner and tighten the bolt to 18 ft. lbs. (25 Nm).
  48.  
  49. Remove the paper clip and allow the tensioner to load.
  50.  
  51. Install the right side drive chain guide and shoe and tighten the bolts to 18 ft. lbs. (25 Nm).
  52.  
  53. Guide the right timing chain through the cylinder head and onto the outer row of the intermediate drive chain sprocket teeth.
  54.  
  55. Install the right camshaft position actuators into the drive chain.
  56.  
  57. Install the camshaft sprockets on the camshafts.
    NOTE
    Ensure the camshaft sprockets notches marked RI or RE engage the proper camshaft pins.

  58.  
  59. Loosely install the actuator oil control valves.
  60.  
  61. Verify that the camshaft sprocket notches and the camshaft pins are 90° perpendicular to each other.
  62.  
  63. Install camshaft locking tool J-46328 to the right camshafts.
  64.  
  65. Install the upper drive chain shoe guide bolt and then tighten the upper and lower bolts to 18 ft. lbs. (25 Nm).
  66.  
  67. Holding the right drive chain tensioner in one hand, rotate the ratchet release lever counterclockwise with the other hand and place a paper clip to hold it.
  68.  
  69. Collapse the tensioner shoe and hold while slowly releasing the ratchet lever to relive tension on the shoe.
  70.  
  71. Install the chain tensioner and tighten the bolt to 18 ft. lbs. (25 Nm).
  72.  
  73. Remove the paper clip and allow the tensioner to load.
  74.  
  75. Ensure the correct alignment of all timing chain marks.
  76.  
  77. Tighten all 4 oil control valves, holding the camshaft flats to prevent camshaft rotation. Tighten the oil control valve bolts to 90 ft. lbs. (120 Nm).
  78.  
  79. Remove the camshaft holding tools.
  80.  
  81. Install a new gasket to the right side camshaft actuator housing, install the housing and tighten the bolts to 89 inch lbs. (10 Nm).
    NOTE
    The camshaft position actuators solenoids must be precisely aligned to the camshaft position actuator oil control valves on the ends of the camshafts. This is done with an alignment pin. Failure to align the solenoids correctly can lead to poor engine performance and component damage.

  82.  
  83. Fabricate an alignment pin using a 15/64 inch drill bit at least 2 inches long.
  84.  
  85. Verify the alignment pin will pass through intake actuator solenoid alignment hole and the control valve alignment hole.
  86.  
  87. Apply a bead of RTV sealant around the actuator solenoid flange.
  88.  
  89. Install the actuator over the oil control valve and insert the alignment pin to align the valve to the solenoid.
  90.  
  91. Tighten the actuator solenoid bolts to 71 inch lbs. (8 Nm).
  92.  
  93. Install a new actuator solenoid plug.
  94.  
  95. Repeat this procedure on the right exhaust actuator solenoid, and both left side actuator solenoids.
  96.  
  97. Install the oil pump.
  98.  
  99. Clean the front cover gasket surface.
  100.  
  101. Place a small amount of sealant to the split line of the upper and lower crankcases and the top edge of the block face.
  102.  
  103. Install a new front cover gasket over the crankcase dowel pins.
  104.  
  105. Install the front cover and hand tighten the bolts.
  106.  
  107. Tighten the front cover bolts in the sequence shown to 106 inch lbs. (12 Nm).

    Click image to see an enlarged view

    Fig. Engine front cover bolt tightening sequence-4.6L engine

  108.  
  109. Install the 4 CMP sensors and tighten to 89 inch lbs. (10 Nm).
  110.  
  111. Install the camshaft covers
  112.  
  113. Press the crankshaft damper on.
  114.  
  115. Coat the damper bolt with clean engine oil, install the bolt and tighten to 37 ft. lbs. (50 Nm), plus an additional 120°.
  116.  
  117. Remove the crankshaft holding tool from the starter opening and install the starter.
  118.  
  119. Install the water pump pulley and tighten the bolts to 89 inch lbs. (10 Nm).
  120.  
  121. Install the drive belt idler pulley and tighten to 37 ft. lbs. (50 Nm).
  122.  
  123. Install or connect the following:

    Fan adapter, if equipped
     
    Drive belt tensioners
     
    Accessory drive belts
     
    Radiator hoses
     
    Engine appearance cover
     
    Air outlet duct
     
    Negative battery cable
     

  124.  
  125. Fill the cooling system to the correct level.
  126.  
  127. Fill the engine with oil to the correct level.
  128.  
  129. Start the engine and verify proper operation.
  130.  

 
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