Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Drain the engine oil.
4. Remove or disconnect the following:
   • Negative battery cable
   • Intake manifold
   • Accessory drive belt
   • Intake Manifold Runner Control (IMRC) actuator
   • Spark plug wires
   • Ignition coil
   • Exhaust front pipe
   • Oil pan
   • Alternator and bracket
   • A/C compressor
   • Wiring harness connector bracket
   • Water pump drive belt and pulley
   • Camshaft oil seal housing
   • Valve covers
   • Right motor mount and bracket
   • Crankshaft pulley
   • Front crankshaft seal
   • Front cover. Loosen the bolts in the sequence shown.

     Fig. 1: Front cover bolt removal sequence — 2.5L engine

   • Crankshaft Position (CKP) sensor pulse wheel
5. Rotate the crankshaft so that the keyway is at the 11 o'clock position to locate the crankshaft at TDC for No. 1 cylinder.
6. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck.

   Fig. 2: Camshaft alignment with the crankshaft in the 11 o'clock position — 2.5L engine

7. Rotate the crankshaft so that the keyway is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position.

   NOTE: Keep all valvetrain components in order for assembly.

8. Remove or disconnect the following:
   • Right timing chain tensioner
   • Right timing chain tensioner arm
   • Right timing chain and crankshaft timing sprocket
   • Right bank camshafts
9. Rotate the crankshaft 1 and ²⁄₃ turns and set the crankshaft keyway at the 11 o'clock position. This places the left bank camshafts in the neutral position.
10. Remove or disconnect the following:
    • Left timing chain tensioner
    • Left timing chain tensioner arm
    • Left timing chain and crankshaft timing sprocket

    To install:

11. Prepare the timing chain tensioners for installation as follows:
    1. Place the left chain tensioner in a vise.
    2. Using a small prytool, release and hold the timing chain tensioner ratchet/pawl mechanism through the access hole in the timing chain tensioner.

       Fig. 3: Using a thin prytool, release and hold the timing chain tensioner ratchet/pawl mechanism — 2.5L engine

    3. Slowly compress the tensioner.
    4. Lock the piston with a 1.5mm wire or paperclip.
    5. Repeat for the right chain tensioner.

       Fig. 4: Left bank timing chain alignment — 2.5L engine

       NOTE: Be sure that the crankshaft keyway is still at the 11 o'clock position.

12. Install or connect the following:
    • Left timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
    • Left timing chain tensioner arm
    • Left timing chain tensioner. Tighten the retaining bolts to 15–22 ft. lbs. (20–30 Nm).
13. Remove the left timing chain tensioner retaining wire.
14. Rotate the crankshaft so that the keyway is at the 3 o'clock position.
15. Install the right bank camshafts with the exhaust camshaft index mark at 12 o'clock and the intake camshaft index mark at 3 o'clock as shown.

    Fig. 5: Right bank camshaft positioning — 2.5L engine

    Fig. 6: Right bank timing chain alignment — 2.5L engine

16. Install or connect the following:
    • Right timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
    • Right timing chain tensioner arm
    • Right timing chain tensioner. Tighten the retaining bolts to 15–22 ft. lbs. (20–30 Nm).
17. Remove the right timing chain tensioner retaining wire.
18. Install or connect the following:
    • CKP sensor pulse wheel
    • Front cover. Tighten the bolts in the reverse of the loosening sequence to 15–22 ft. lbs. (20–30 Nm).
    • Front crankshaft seal
    • Crankshaft pulley
19. Tighten the crankshaft pulley bolt as follows:
    1. Step 1: 88 ft. lbs. (120 Nm)
    2. Step 2: Loosen the bolt one turn
    3. Step 3: 35–39 ft. lbs. (47–53 Nm)
    4. Step 4: Plus 85–95 degrees
20. Install or connect the following:
    • Right motor mount and bracket
    • Valve covers
    • Camshaft oil seal housing
    • Water pump drive belt and pulley
    • Wiring harness connector bracket
    • A/C compressor
    • Alternator and bracket
    • Oil pan
    • Exhaust front pipe
    • Ignition coil
    • Spark plug wires
    • IMRC actuator
    • Accessory drive belt
    • Intake manifold
    • Negative battery cable
21. Fill the crankcase to the correct level.
22. Start the engine and check for leaks.