Sonata timing chain changed now engine feels very tight, sometimes goes away but returns

There is a tensioner and being loose is not as bad as wear, you might notice some backfire noise when the wear gets excessive.

Did you take pictures while removing the originals? It's always a good habit. Below are the instructions you need to follow. Your own pics are very helpful when doing a big job like this.

1. Disconnect negative battery (1) cable.
2. Drain cooling system.
3. Remove upper intake manifold.
4. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.

CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

1. Align crankshaft sprocket timing mark to mark on oil pump housing (2). The mark on oil pump housing is 600 ATDC of #1 cylinder.

CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

1. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head.

1. Disconnect and remove camshaft position sensor (4) from left cylinder head.
2. Remove timing chain guide access plugs (3) from cylinder heads.

NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.

1. Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper (1) (if equipped) and sprocket.
2. Remove left side camshaft sprocket attaching bolts and remove sprocket.
3. Remove lower chain guide (7) and tensioner arm (8).
4. Remove the primary timing chain (5).
5. Remove crankshaft sprocket (6).

INSTALLATION

1. Inspect all sprockets (4,9,11) and chain guides (2,5,10). Replace if worn.
2. For crankshaft sprocket installation procedures Refer to CRANKSHAFT SPROCKET.
3. If removed, install right and left side short chain guides (11). Tighten attaching bolts to 28 Nm (250 inch lbs.) .
4. Align crankshaft sprocket timing mark to the mark on oil pump housing (3).

NOTE: Lubricate timing chain and guides with engine oil before installation.

1. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (1).

1. Lower the primary chain with left side sprocket through the left cylinder head opening.

NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.

1. Loosely position left side camshaft sprocket over camshaft hub.
2. Align timing (plated) link to the crankshaft sprocket timing mark (3).
3. Position primary chain onto water pump drive sprocket (10).
4. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely position over camshaft hub.
5. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
6. Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 28 Nm (250 inch lbs.) .

NOTE: Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

1. Install chain guide access plugs to cylinder heads. Tighten plugs to 20 Nm (15 ft. lbs.) .

NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

1. Purge oil from timing chain tensioner using the following procedure:

1. Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
2. Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

1. Reset timing chain tensioner using the following procedure:

1. Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
2. Apply a downward force until tensioner is reset.

NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball.

CAUTION: Ensure the tensioner is properly reset. The tensioner body (4) must bottom against the top edge of Special Tool 8186 (3). Failure to properly perform the resetting procedure may cause tensioner jamming.

NOTE: Inspect the tensioner O-ring (2) for nicks or cuts and make sure the snap ring (1) is correctly installed, replace as necessary.

1. Install the reset chain tensioner (1) into the right cylinder head.
2. Position tensioner retaining plate (2) and tighten bolts (1) to 12 Nm (105 inch lbs.) .

1. Starting at the right cylinder bank, first position the camshaft damper (1) (if equipped) on camshaft hub, then insert a 3/8 square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 inch lbs.) .
2. Turn the left side camshaft by inserting a 3/8 square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 inch lbs.).
3. Rotate engine slightly clockwise to remove timing chain slack, if necessary.

1. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then release the tensioner arm. Verify the tensioner is activated (extends).

1. Install camshaft position sensor (2) and connect electrical connector.
2. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
3. Install upper intake manifold.

NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds.

1. Fill cooling system.

Removal & Installation

3.5L Engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Record the radio anti theft code data.
3. Remove or disconnect the following:
   
   Negative battery cable Engine cover Accessory drive belts Idler pulley Crankshaft pulley Power steering pump pulley Belt tensioner pulley Upper and lower timing belt covers
   
4. Support the engine with a floor jack and remove the engine mount.
5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.
   
   

   Fig. Timing belt routing and timing marks-3.5L Engine
   

6. Remove or disconnect the following:
   
   Auto tensioner Timing belt
   
   

   Fig. Timing belt and related components-3.5L Engine
   
   

To install:

1. Ensure that the engine is set to Top Dead Center (TDC).
2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
3. Install the timing belt in the following order:
   1. Crankshaft sprocket
   2. Idler pulley
   3. Left bank exhaust camshaft sprocket
   4. Left bank intake camshaft sprocket
   5. Water pump pulley
   6. Right bank intake camshaft sprocket
   7. Right bank exhaust camshaft sprocket
   8. Tensioner pulley
   
   
4. Install the auto tensioner. Do not remove the retaining pin at this time.
5. Check that the crankshaft and camshaft timing marks are aligned correctly.
6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
8. Loosen the tensioner pulley center bolt.
9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).
   
   

   Fig. Adjusting the tensioner pulley-3.5L Engine
   

10. Remove the auto tensioner retaining pin.
11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.
    
    

    Fig. Measuring the auto tensioner rod-3.5L Engine
    

13. When the auto tensioner measurement is correct, install or connect the following:
    
    Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable
    
14. Reprogram the radio anti theft codes.

    Kia_Sedona_2002-2006
    Timing Chain, Sprockets, Front Cover & Seal

    • REMOVAL & INSTALLATION

    Print
    

    
    Removal & Installation
    
    3.8L Engine
    

    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Record the radio anti theft code data.
    3. Remove the engine from the vehicle.
    4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
    5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
    6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
    7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
    10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
    11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
        NOTE Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
        
    12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
    13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
    14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
    15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
    16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.
        
        

        Fig. Timing chain and related components-3.8L Engine
        

    
    To install:
    
    1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
    2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
    3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
    4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
    5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
    6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
    7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
       
       

       Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine
       

    8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
    9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
    10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
    11. Install the crankshaft sprocket, oil pump and right camshaft drive.
    12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
    13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
    14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
        
        

        Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine
        

    15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
    16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
    17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
    18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
    19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
    20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
    21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
    22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
        NOTE Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Sealant application (1 inch bead width)-3.8L Engine
        

    23. Apply sealant on the chain cover.
        NOTE The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Timing cover sealant application-3.8L Engine
        

    24. Install a new gasket to the timing case cover.
        NOTE It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.
        
        
        

        Fig. Timing cover gasket installation (A) gaskets-3.8L Engine
        

    25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.
        
        

        Fig. Timing cover bolt torque sequence and specification-3.8L Engine
        

    26. Install the timing case cover oil seal.
    27. Continue the installation in the reverse order of the removal procedure.

Procedure is pasted below. Please let me know if you have questions.
Removal & Installation2.2L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove or disconnect the following:
   NOTE The timing chain has 2 matching colored links and 1 uniquely colored link.
   Negative battery cable, PCV hose, Fuel line bracket, Ignition coil and module assembly Ground strap from camshaft cover, Camshaft cover, Front fender liner, Accessory drive belt Crankshaft balancer pulley, Accessory drive belt tensioner, Front cover-to-water pump bolt Remaining front cover bolts, Front cover
   
5. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link (2) at the 5 o-clock position.
6. Confirm that the INT diamond on the intake camshaft sprocket is aligned with the uniquely colored link at (1) the 2 o-clock position.
7. Confirm that the EXH triangle on the exhaust camshaft sprocket is aligned with the matching colored link (3).
8. Remove or disconnect the following:
   NOTE Use a 24 mm wrench to hold the camshafts to prevent them from turning.
   Timing chain tensioner, Fixed timing chain guide access plug, Fixed timing chain guide Upper timing chain guide, Exhaust camshaft sprocket, Timing chain tensioner guide Intake camshaft sprocket, Timing chain through the top of the cylinder head Crankshaft sprocket
   
   
   

   Fig. Lining up the crankshaft sprocket mark with the colored link in the 5 o-clock position (2).
   
   
   
   

   Fig. Aligning the intake camshaft sprocket mark with the colored link in the 2 o-clock position (1).
   
   
   
   

   Fig. Aligning the exhaust camshaft sprocket (3).
   

To install:

1. Install the crankshaft sprocket with the timing mark in the 5 o-clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head.
4. Route the timing chain around the crankshaft sprocket and line up the first marching colored link (2) with the timing mark on the crankshaft sprocket.
5. Install the exhaust camshaft sprocket with a new bolt loosely onto the exhaust camshaft.
6. Align the timing mark on the sprocket with the last matching colored (3).
7. If necessary, align the camshaft as follows:
   1. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft.
   2. Turn the crankshaft 45 degrees in either direction.
   3. Turn the intake camshaft to the appropriate location.
   4. Turn the crankshaft back to top dead center (TDC).
8. When the sprocket seats in on the camshaft, tighten the sprocket bolt hand tight.
9. Verify all of the colored links and the appropriate timing marks are still aligned.
10. Install the fixed timing chain guide. Tighten the bolts to 133 inch lbs. (15 Nm).
11. Install the upper timing chain guide. Tighten the bolts to 89 inch lbs. (10 Nm).
12. Using a 24 mm wrench to hold the camshafts, tighten the camshaft sprocket bolts 63 ft. lbs. (85 Nm) plus 30 degrees.
13. Measure the timing chain tensioner 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 inches (72 mm) front end to end. A tensioner in the active state will measure 3.35 inches (85 mm) from end to end.
14. 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. Install the bottom half of the Tensioner tool J-45027-2 into a vise.
    3. Install the notch end of the piston assembly into the bottom half of the tensioner tool.
    4. Using the top half of the Tensioner tool J-45027-1, turn the ratchet cylinder into the piston.
    5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore.
    
    
15. Install the timing chain tensioner assembly. Tighten to 66 ft. lbs. (75 Nm).
16. Release the timing chain tensioner by compressing it approximately 0.08 inches (2mm). Feed a rubber-tipped tool down through the cam drive chest to reset on the cam chain. Give the tool a sharp jolt diagonally downwards to release the tensioner.
17. Install the timing chain oiling nozzle.
18. Install the timing chain guide bolt access hold plug with silicone sealant on the threads. Tighten the plug to 59 ft. lbs. (90 Nm).
19. Install or connect the following:
    
    Camshaft cover. Tighten the bolts to 89 inch lbs. (10 Nm). Front cover with new gasket. Tighten the bolts to 18 ft. lbs. (25 Nm). Accessory drive belt tensioner. Tighten the bolts to 33 ft. lbs. (45 Nm). Crankshaft balancer pulley using a new bolt. Tighten the bolt to 74 ft. lbs. (100 Nm) plus 75 degrees. Accessory drive belt, Front fender liner, Ground strap to camshaft cover Ignition coil and module assembly, Fuel line bracket, Air intake assembly, Negative battery cable
20. Refill the cooling system to the correct level.
21. Refill the engine with oil to the correct level.
22. Start the engine and check for leaks.
    
    
    

    Fig. Compressing the timing chain tensioner-2.2L engine.
    

Timing Chain and Gears REMOVAL & INSTALLATION 1.9L Engine NOTE: The following procedure requires the use of the puller tool No. J-25031 or equivalent, and timing sprocket installation tool No. J-26587 or equivalent.

1. Remove the timing (front) cover from the engine.
2. Lock the shoe on the automatic adjuster in fully retracted position by depressing the adjuster lock lever. NOTE: To remove the timing chain, it may be necessary to remove the camshaft sprocket. Before removing the timing chain, be sure to align the timing marks.
   
3. Remove timing chain from crankshaft sprocket.
4. Check the timing sprockets for wear or damage. If crankshaft sprocket must be replaced, remove the sprocket and the pinion gear from crankshaft using the puller tool No. J-25031 or equivalent.
5. Check timing chain for wear or damage; replace as necessary. Measure distance "L'' (40 links) with the chain stretched with a pull of approximately 22 lbs. (98N). Standard "L'' value is 15 in. (381mm); replace chain if "L'' is greater than 15.16 in. (385mm).
6. Remove the automatic chain adjuster-to-engine bolt and the adjuster.
7. To check the operation of the automatic chain adjuster, push the shoe inwards, if it becomes locked, the adjuster is working properly. The adjuster assembly must be replaced if rack teeth are found to be worn excessively.
8. To remove the chain tensioner, remove the "E'' clip and the tensioner. Check the tensioner for wear or damage; if necessary, replace it. Fig. 1: Timing chain guide and tensioner - 1.9L engine
   
   
9. Inspect the tensioner pin for wear or damage. If replacement is necessary, remove the pin from the cylinder block using a pair of locking pliers. Lubricate the NEW pin tensioner with clean engine oil. Start the pin into block, then place the tensioner over the appropriate pin. Position the E-clip onto the pin, then (using a hammer) tap it into the block until clip just clears tensioner. Check the tensioner and adjuster for freedom of rotation on the pins.
10. Inspect the guide for wear or damage and plugged lower oil jet. If replacement or cleaning is necessary, remove the guide bolts, the guide and the oil jet. Install a new guide and upper attaching bolt. Install the lower oil jet and bolt, so that the oil port is pointed toward crankshaft. To install: Fig. 2: Timing chain alignment and installation - 1.9L engine
    Fig. 3: Inspecting the timing chain for wear
    
    
11. Install the timing sprocket and the pinion gear (groove-side toward the front cover). Align the key groove with crankshaft key, then drive it into position using installation tool No. J-26587 or equivalent.
12. Turn the crankshaft so that key is turned toward the cylinder head-side (No. 1 and No. 4 pistons at TDC).
13. Install the timing chain, align the timing chain mark plate with the mark on the crankshaft timing sprocket. The side of the chain with the mark plate is on the front-side and the side of chain with the most links between mark plates is on the chain guide-side. Keep the timing chain engaged with the camshaft timing sprocket until the camshaft timing sprocket is installed on the camshaft.
14. Install the camshaft timing sprocket so that it's marked-side faces forward and it's triangular mark aligns with the chain mark plate.
15. Install the automatic chain adjuster.
16. Release the lock by depressing the shoe on adjuster by hand, and check to make certain the chain is properly tensioned when the lock is released.
17. Install the timing cover assembly.

Timing Chain and Sprockets
REMOVAL & INSTALLATION

1. 
   
   
   
   Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing
   mark and keyway will align with the main bearing cap split line
   
   
   
   
   
   
   
   Fig. 2: Exploded view of the timing chain and sprocket
   assembly - SOHC engine
   
   
   
   
   
   
   
   Fig. 3: Insert the timing pin to ensure that the camshaft is at
   No. 1 TDC - SOHC engine
   
   
   
   
   
   
   
   Fig. 4: When the camshaft is at TDC, rotate the crankshaft
   counterclockwise 90 degrees to achieve TDC
   
   

DOHC Engine

1. Disconnect the negative battery cable.
   
2. Remove the timing chain front cover.
   NOTE: During timing chain and sprocket removal, position the
   crankshaft 90 degrees past Top Dead Center (TDC) to make sure the pistons will
   not contact the valves upon assembly.
   
   
   
3. Carefully rotate the crankshaft clockwise so the timing mark on the
   crankshaft sprocket and keyway align with the main bearing cap split line.
   
4. Remove the bolts, then remove the timing guides and tensioner.
   
5. Remove the camshaft sprocket bolts, using a 7?8 in. (21mm) wrench
   to hold the camshaft. Then remove the timing chain and camshaft sprocket. Remove
   the crankshaft sprocket, if necessary.
   To install:
   
   
6. Inspect the chain for wear and damage. Check the inside diameter of the
   chain, it should be no more than 23.15 in. (588mm). Inspect the chain guides for
   wear or cracks and the timing sprockets for teeth or key wear. Replace
   components as necessary.
   
7. Verify that the crankshaft is positioned 90 degrees clockwise past TDC. The
   crankshaft keyway should be at 3 o'clock aligned with the main bearing cap split
   line to prevent piston and valve damage.
   
8. Install the camshaft sprockets, retaining bolts and washers. Make sure the
   letters FRT on the sprockets face forward, away from the cylinder block. Use the
   wrench flats provided on the camshafts to hold the shaft and tighten the bolts
   to 75 ft. lbs. (102 Nm).
   
9. Bring the camshafts up to No. 1 TDC by rotating the camshafts and sprocket
   until the dowel pins are at 12 o'clock. Install a 1?6 in. drill bit
   into the hole in the sprocket about 9 o'clock.
   
10. If removed, install the crankshaft sprocket, then rotate the crankshaft
    counterclockwise 90 degree up to No. 1 TDC (keyway and sprocket timing mark at
    12 o'clock, in alignment with the block timing mark).
    
11. Position the timing chain under the crankshaft sprocket and over the
    camshaft sprockets so 2 silver link plates align with the reference marks on the
    camshaft sprockets and another 2 plates align with the downward tooth (at 6
    o'clock position) on the crankshaft sprocket. Excess chain slack should be
    located on the tensioner side of the cylinder block.
    
12. Verify that the crankshaft reference mark aligns with the cylinder block
    mark at 12 o'clock and that the timing pins are installed in the holes at about
    the 9 o'clock position. Remove the timing pins from the camshaft sprockets.
    
13. Install the timing chain fixed guide to the right of the block face toward
    the water pump. Tighten the bolts to 21 ft. lbs. (28 Nm) and verify the chain is
    snug against the guide.
    
14. Install the pivoting chain guide and check for clearance between the block
    and head. Tighten the bolt to 19 ft. lbs. (26 Nm) and verify the guide pivots
    freely.
    
15. Install the 2 forward camshaft bearing caps and the upper timing chain
    guide, then tighten the retaining bolts to 124 inch lbs. (14 Nm).
    
16. Retract the tensioner plunger and pin the ratchet lever using a 1?8 in. (3.18mm) No.
    31 drill bit inserted in the alignment hole at the lower front of the component.
    Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove
    the drill bit.
    
17. Make one final check to verify all components are properly timed, then
    remove all timing pins.
    
18. Install the timing chain front cover.
    
19. Connect the negative battery cable, start the engine and check for leaks.
    
    
    
    
    
    Fig. 5: Rotate the crankshaft clockwise until the timing mark
    on the crankshaft sprocket and keyway align with the main bearing cap split line
    
    
    
    
    
    
    
    
    Fig. 6: Loosen the timing chain tensioner mounting bolt . . .
    
    
    
    
    
    
    
    Fig. 7: . . . and remove the tensioner from the engine block
    
    
    
    
    
    
    
    Fig. 8: Retract the tensioner plunger and pin the ratchet lever
    with a 1?8
    in. (3.18mm) drill bit inserted in the alignment hole
    
    
    
    
    
    
    
    Fig. 9: Remove the mounting fasteners from both timing guides .
    . .
    
    
    
    
    
    
    
    Fig. 10: . . . and remove the timing guides from the engine
    
    
    
    
    
    
    
    Fig. 11: Remove the camshaft sprocket bolts, using a 7?8 in. (21mm) wrench
    to hold the camshaft
    
    
    
    
    
    
    
    Fig. 12: Remove the timing chain and camshaft sprockets
    
    
    
    
    
    
    
    Fig. 13: Insert the timing pins to verify that the camshafts
    are at TDC
    
    
    
    
    
    
    
    Fig. 14: Make sure that the silver link plates and reference
    marks are all in alignment as shown
    
    

Assuming you have the single overhead camshaft, there is a pin you're supposed to use to align the camshaft gear--see below diagram from autozone.com:


Obviously you could substitute a phillips screwdriver of the appropriate size for the alignment pin shown. Leave it in until you complete the chain installation.

The crankshaft pully mark goes straight up:

Make sure the chain is tight on the right side when the gears are in these positions and that it doesn't slip any teeth on eight gear when you apply the tensioner. I will paste the autozone instructions below.

To install:

1. Inspect the chain for wear and damage. Check the inside diameter of the chain, it should be no more than 16.77 in. (426mm). Inspect the chain guides for wear or cracks and the timing sprockets for teeth or key wear. Replace components as necessary.
2. Verify that the crankshaft is positioned 90 degrees clockwise past TDC from the keyway (keyway at 3 o'clock).
3. Bring the camshaft up to No. 1 TDC by loosely installing the sprocket and rotating the sprocket until the timing pin can be inserted. The camshaft contains wrench flats to assist in turning the shaft. The dowel pin should be at 12 o'clock when the camshaft is at TDC and a timing pin ( 3 / 16 in. drill bit) should then install at about the 8 o'clock position.
4. If removed, install the crankshaft sprocket, then rotate the crankshaft counterclockwise 90 degrees up to No. 1 TDC (keyway at 12 o'clock).
5. Position the chain under the crankshaft sprocket and over the camshaft sprocket. If necessary remove the camshaft sprocket, then slide the camshaft sprocket into position with the chain already engaged. The timing chain should be positioned so that one silver link plate aligns with the reference mark on the camshaft sprocket and the other aligns with the downward tooth (at the 6 o'clock position) on the crankshaft sprocket. The letters FRT on the camshaft sprocket must face forward, away from the cylinder head and excess chain slack should be located on the tensioner side of the block.
6. Temporarily install the timing pin to verify proper alignment of the camshaft and sprocket, then install and tighten the sprocket bolt to 75 ft. lbs. (102 Nm). Again, use a wrench on the camshaft flats to hold the shaft in position while tightening the bolt. Do not allow the camshaft retaining bolt to torque against the timing pin or cylinder head damage will result.
7. Install the chain guides with the words FRONT facing out. Install the fixed guide first and verify the chain is snug against the guide, then install the pivot guide. Tighten the bolts to 19 ft. lbs. (26 Nm) and verify that the pivot guide moves freely.
8. Retract the tensioner plunger and pin the ratchet lever using a 1 / 8 in. No. 31 drill bit inserted in the alignment hole at the bottom front of the component. Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove the drill bit.
9. Make one final check to verify all components are properly timed, then remove all timing pins.
10. Install the timing chain front cover.
11. Connect the negative battery cable, start the engine and check for leaks.

.

1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.

1. Remove the crankshaft sensor ring from the crankshaft.

1. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.

1. Using the special tool, position the crankshaft as shown.
   

1. Install the special tool.

1. NOTE: LH shown; RH similar.
   Remove the two bolts, the timing chain tensioner and tensioner arm.

1. Remove the LH and RH timing chains and the crankshaft sprockets.
   
   • Remove the special tool from the crankshaft.
   • Remove the timing chains from the camshaft sprockets.
   • Remove the right and left timing chains and the crankshaft sprocket from the crankshaft.

1. CAUTION: The bolts are different lengths and must be returned to their original location.
   NOTE: LH shown; RH similar.
   Remove the bolts and the timing chain guides.

Installation

1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
   CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
   Compress the tensioner plunger, using an edge of a vise.

1. Using a small screwdriver or pick, push back and hold the ratchet mechanism.

1. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

1. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.

1. Remove the tensioner from the vise.

1. NOTE: There are 61 links in the timing chain.
   If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.

1. Install the timing chain guides.

1. Using the special tool, verify correct crankshaft position.
   • Remove the special tool.

1. NOTE: Crankshaft sprockets are identical. They can only be installed one way. Refer to the following illustration for correct crankshaft sprocket installation.
   If removed, install LH and RH crankshaft sprockets.

1. Install the LH timing chain onto the crankshaft sprocket, aligning the one copper (marked) link on the timing chain with the slot on the crankshaft sprocket.

1. Position the LH timing chain on the camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.

1. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

1. Position the RH timing chain on the camshaft sprocket. Make sure the two copper (marked) links align with the camshaft sprocket timing mark.

1. NOTE: LH shown; RH similar.
   Position the tensioner arms and tensioners, and install the bolts.

1. Remove the tensioner retaining clip.

1. As a post-check, verify correct alignment of all timing marks.

1. Remove the special tool.

1. Position the crankshaft sensor ring on the crankshaft.

1. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.

Your timing chain tensioner is using oil pressure to stay tight.Could be your oil pressure is so low at idle the tensioner just can't stay tight.At the next oil change you could go for a thicker oil and see if the tensioner keeps the chain tighter at idle.

Here is All Lititure But Pictures Wont show up on FixYa for some reason, I can Email it ALL to you Just Send Me A Request to my Nickname here @aol.com


SPECIAL TOOLS REQUIRED (or equivalents)

• J-36008, Camshaft sprocket timing alignment pins.
• J-39579, Camshaft sprocket wrench.

CAUTIONS:

• The timing chain on the 1996 LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam Engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used.
• The timing chain and crankshaft sprocket MUST be marked so that they are reinstalled with the same side facing out at the time of reassembly.
• Failure to follow the removal and installation procedures could result in severe engine damage.

REMOVE OR DISCONNECT

1. Negative battery cable.
2. Front cover, refer to Timing Cover / Service and Repair .
3. Rotate crankshaft in clockwise direction until camshaft and crankshaft timing marks are aligned.
4. Timing chain guides.
5. Raise and support vehicle.
6. Ensure slack in timing chain is above tensioner assembly, then remove chain tensioner. The timing chain must be disengaged from grooves in tensioner shoe to permit removal of shoe. Position a suitable screwdriver under timing chain while pulling shoe outward. If difficulty is encountered in removing tensioner shoe, proceed as follows:

1. Lower vehicle, then while holding the intake camshaft sprocket with J-39579, remove sprocket bolt and washer.
2. Remove washer, then install bolt into camshaft by hand.
3. Position a suitable three jaw puller into intake camshaft sprocket relief holes and remove sprocket. CAUTION: Do NOT pry on camshaft sprocket as damage to sprocket or timing chain housing may result.

1. Tensioner assembly attaching bolts and tensioner assembly.
2. MARK CRANKSHAFT SPROCKET AND TIMING CHAIN outer surface for reassembly.
3. Timing chain.

INSTALL OR CONNECT

1. Intake camshaft sprocket onto camshaft with surface marked during removal showing.
2. Intake camshaft sprocket retaining bolt and washer, torque to 70 Nm (52 ft lbs) while holding the sprocket with J-39579 (if removed).
3. Timing pins, J-36008, through holes in camshaft sprockets into holes in timing chain housing to position camshafts for proper timing. If camshafts are out of position and must be rotated more that 1/8 turn to insert timing pins:

1. Crankshaft MUST be rotated 90°clockwise off of TDC in order to give the valves adequate clearance to open.
2. Once the camshafts are in position and the timing pins have been installed rotate crankshaft COUNTERCLOCKWISE to TDC. CAUTION: Do NOT rotate the crankshaft clockwise to TDC, valve or piston damage could occur.

1. Timing chain over exhaust camshaft sprocket, around idler sprocket and around crankshaft sprocket.
2. Set camshaft sprockets at timed position and install timing chain. Remove timing pin from intake camshaft. Using J-39579, rotate the intake camshaft sprocket counterclockwise until timing chain can be installed over sprocket. Release J-39579 after timing chain has been installed over sprocket. The length of chain between intake and exhaust camshaft sprockets should tighten. The timing pin should easily fit through intake camshaft sprocket timing hole into timing chain housing timing hole. If timing pin does not fully index, the camshafts are NOT timed correctly and the procedure MUST be repeated.
3. With timing pins installed, raise and support vehicle.
4. With slack removed from timing chain between intake camshaft sprocket and crankshaft sprocket, timing marks on crankshaft and engine block should be aligned. If the marks are not aligned, move timing chain one tooth forward or rearward to align marks. Remove slack and recheck marks.
5. Reload tensioner assembly to zero position as follows:

1. Form a keeper out of heavy gauge wire into a U-shaped piece with a half inch opening.
2. Apply slight force on tensioner blade to compress plunger.
3. Insert small screwdriver into reset access hole and pry rachet pawl away from ratchet teeth while forcing the plunger completely in the hole.
4. Install keeper between access hole and blade.

1. Tensioner assembly to chain housing and recheck plunger assembly installation, noting long end is toward crankshaft.
2. Tighten timing chain tensioner bolts to 10 Nm (89 in lbs) .
3. Lower vehicle to point where timing pins can be removed from camshaft sprockets.
4. Rotate crankshaft two revolutions in the clockwise direction. Align crankshaft keyway with the mark on cylinder block and reinstall timing pins through camshaft sprockets into housing timing holes. Timing pins should slide easily through timing holes. If timing pins cannot be inserted easily, repeat procedure to properly time engine. CAUTION: If the engine is not correctly timed, severe engine damage could occur.
5. Timing chain guides.
6. Engine front cover.
7. Negative battery cable.