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Posted on Apr 16, 2010
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How do i tighten the timing chain - 2003 Hyosung RX 125

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The timing chain should be self adjusting, spring tension takes up the slack as the chain wears. If your timing chain is noisy, or rattling, then it is worn out and needs to be replaced.

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1answer

How do I put a water pump on 2.4 grand am
There are a lot of steps, and you need to take your time. You will need access to a lift or jack stand, and make sure you keep the work area clean and organised, taking photos of the timing system will make your life easier when it comes to re-timing the engine.

Water Pump Replacement (2.4L)
Removal Procedure
  1. Drain the coolant. Recover the coolant. Refer to Cooling System Draining and Filling.
  2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Exhaust.
  3. Remove the coolant intake pipe. Refer to Engine Coolant Inlet Pipe Replacement in Engine Cooling.
  4. Lower the vehicle.
  5. Disconnect the heater hose quick connect from the heater outlet pipe.
  6. Remove the timing chain and tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L. (see below procedure)
  7. Remove the water pump cover-to-cylinder block bolts.
  8. Remove water pump pipe to cylinder block bolt.
  9. Remove the 3?water pump-to-timing chain housing nuts.
  10. Remove the water pump and cover assembly.
  11. Remove the water pump cover-to-coolant pump assembly bolts.
  12. Clean all sealing surfaces.
Installation Procedure
    Important: Before you install the coolant pump, read the entire procedure. Follow the tightening sequences in order to avoid part damage and to provide proper sealing.

  1. Install the pump cover bolts. Hand tighten the bolts.
  2. Install water pump cover assembly.
  3. Install the cover-to-block bolts. Hand tighten the bolts.
  4. Install the coolant pump-to-timing chain housing nuts. Hand tighten the nuts.
    5. Notice: Refer to Fastener Notice in Cautions and Notices.
  5. Torque in sequence as follows:
    1. Tighten the water pump-to-timing chain housing nuts.
      Tighten
      Tighten water pump to timing chain housing nuts to 26?Y (19?lb?ft).
    2. Tighten the pump cover-to-pump assembly bolts.
      Tighten
      Tighten the water pump cove to water pump bolts to 14?Y (124?lb?in).
    3. Tighten the coolant pump cover-to-engine block bolts. Tighten the bottom bolt first.
      Tighten
      Tighten water pump to engine block bolts to 26?Y (19?lb?ft).
  6. Install heater hose to pipe on water pump.
  7. Install the exhaust manifold and install new gaskets. Refer to Exhaust Manifold Replacement in Engine Exhaust.
  8. Install oil level indicator tube and indicator. Refer to Oil Level Indicator Tube Replacement in Engine Mechanical-2.4L.
  9. Connect the brake vacuum pipe to the cam housing.
  10. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  11. Install catalytic converter to to manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  12. Install the coolant inlet pipe. Refer to Engine Coolant Inlet Pipe Replacement.
  13. Install the timing chain and tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L.
  14. Lower the vehicle.
  15. Connect the oxygen sensor connector.
  16. Fill cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  17. Inspect the system for leaks.
Camshaft Timing Chain, Sprocket, and Tensioner Replacement
Removal Procedure
    Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
    Notice: The timing chain on the 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 the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of reassembly.
  1. Disconnect the negative battery cable.
  2. Remove the engine front cover. Refer to Engine Front Cover Replacement.
  3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes align with the holes in the timing chain housing.
  4. Set the crankshaft sprocket keyway pointing upwards. Align with the centerline of the cylinder bores. This is the timed position.
  5. Remove the timing chain guides.
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Ensure that all of the slack in the timing chain is above the tensioner assembly.
  8. Remove the timing chain tensioner bolts and the tensioner.
  9. Remove the tensioner shoe. Use a small locking ring plier in order to engage the hole in the locking tab and remove the shoe from the stud.
    10. Notice: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur.
    Important: Mark the timing chain and the crankshaft sprocket prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur.
  10. Mark the crankshaft sprocket and the timing chain outer surface.
  11. Remove the timing chain.
  12. Lower the vehicle.
  13. Holding the intake camshaft sprocket with J 39579, remove the sprocket bolt and washer.
  14. Remove the washer from the bolt and rethread the bolt back into the camshaft.
  15. Using a 3-jaw puller and the relief holes in the sprocket, remove the intake camshaft sprocket.
  16. Repeat this procedure for the exhaust camshaft sprocket.
  17. Clean the old sealant from the bolt with a wire brush.
  18. Clean the threaded hole in the camshaft with a round nylon bristle brush.
  19. Inspect the parts for wear. Replace the parts as necessary.Some scoring of the timing chain shoe and the guides is normal.
  20. Replace the timing chain shoe or guides if the scoring exceeds 1.12?mm (45?in).
Installation Procedure


  1. Use Adhesive/Sealant Compound GM?P/N?12345493 or equivalent on the camshaft sprocket bolt. Install the intake and exhaust camshaft sprockets onto the camshafts with the marked surface showing.Notice: Refer to Fastener Notice in Cautions and Notices.
  2. Install the retaining bolts and washers to the intake and exhaust camshaft sprockets.
  3. Tighten
    Tighten the bolts to 70?Y (52?lb?ft) while holding the sprockets with the J 39579.
  4. Install the J 36800 through the holes in the camshaft sprockets into the holes in the timing chain housing. This will position the camshaft for correct timing.
  5. If the camshafts are out of position (you must rotate the camshaft more than 1/8?turn in order to install the alignment dowel pins), use the following procedure:
    1. Rotate the crankshaft 90?degrees clockwise off of the TDC in order to give the valves adequate clearance to open.
    2. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center.

    6. Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur.
    Important: The side of the timing chain that was marked during removal must be showing when the chain is installed.
  6. Install the timing chain over the exhaust camshaft sprocket, around the coolant pump, and around the crankshaft sprocket.
    1. Remove the alignment dowel pin from the intake camshaft.
    2. Using the J 39579, rotate the intake camshaft sprocket counterclockwise enough in order to slide the timing chain over the intake camshaft sprocket.
    3. Release the J 39579. The length of the chain between the 2?camshaft sprockets will tighten.
    4. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated.
  7. Leave the alignment dowel pins installed.
  8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  9. The timing marks on the crankshaft and on the cylinder block should be aligned when the slack is removed from the chain linking the intake camshaft sprocket and the crankshaft sprocket. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and re-examine the marks.

    10. Important: Use the following steps in order to reset the timing chain tensioner assembly to the zero position.
  10. Reset the timing chain tensioner assembly.
    1. Insert the tensioner plunger assembly into the tensioner housing.
    2. With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface.
    3. With the plunger face against the workbench, press firmly on the bottom of the tensioner housing.
    4. Compress the plunger until the plunger is seated flush in the tensioner.

  11. Check the plunger to make sure the plunger is out of the cylinder at the correct dimension. The correct dimension for the plunger to extend out of the cylinder is 1.7?mm (0.07?in) maximum.

  12. Loosely install the tensioner assembly and bolts to the timing chain housing.
  13. Install the timing chain tensioner shoe on the stud.
  14. Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud.
  15. Tighten the timing chain tensioner bolts. Do Not overtighten.
    Tighten
    Tighten the bolts to 10?Y (89?lb?in).


    16. Important: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started.
  16. Release the timing chain tensioner plunger.
    1. Using a flat blade screwdriver, cotter pin remover, or similar tool, press firmly against the face of the timing chain tensioner plunger.
      2. Important: If the timing chain tensioner cannot be depressed, the plunger is not properly reset and the procedure for resetting the timing chain tensioner should be repeated.
    2. Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner.
    3. Release the tensioner plunger. the plunger should press firmly against the back of the timing chain tensioner shoe.
  17. Remove J 36800 from the camshaft sprockets.
  18. Rotate the crankshaft clockwise 2?full rotations. Align the crankshaft keyway with the mark on the cylinder block, and reinstall the alignment dowel pins. The pins should slide in easily if the engine is timed correctly.

  19. Install the timing chain guides.
  20. Install the engine front cover. Refer to Engine Front Cover Replacement.
  21. Connect the negative battery cable.
    Tighten
    Tighten the bolt to 16?Y (12?lb?ft).
Read full answer
Jul 02, 2016 • Cars & Trucks
0helpful
1answer

How do I set timing on a 2.3 Suzuki aerio engine
wow no job stated.
04 (2.3L) ill take a wild guess and say, you might be fiddling the cam
and doing something there, new cam, new lifters, new chain, new head, ? what?
FSM means factory service manual, ever heard of one?

the FSM is just lousy 4 bucks why not read that first. and not mess it up.

https://suzukipitstopplus.com/Products/1004-2004-aerio-service-manual.aspx

you said SET, so i can only assume its all apart. right then
you want to Instal the chain and time it, right so here are the fsm steps
no photos. log in and read the FSM for that.
  1. Check that match mark on crankshaft timing sprocket is in match with timing mark on lower crankcase.
  2. Install crankshaft timing sprocket as shown in figure.
  3. Apply oil to bush of idler sprocket and install idler sprocket and sprocket shaft.
  4. Install first timing chain by aligning dark blue plate of first timing chain and match mark on idler sprocket.
  5. Bring yellow plate of first timing chain into match with match mark on crankshaft timing sprocket.
  6. Apply engine oil to sliding surface of timing chain tensioner and then install it as shown in figure. Tighten tensioner nut to 18 ft. lbs. (25 Nm).
  7. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch and body. After inserting it, check to make sure that plunger will not come out.
  8. Install timing chain tensioner adjuster No.1. Tighten the timing chain tensioner adjuster No. 1 bolt to 8 ft. lbs. (11 Nm).
  9. Pull out stopper from adjuster No.1.
  10. Apply engine oil to sliding surface of timing chain guide No.1 and then install it. Tighten guide bolts to 6.5 ft. lbs. (9 Nm).
  11. Check that dark blue and yellow plates of first timing chain are in match with match marks on sprockets respectively.
  12. Install second timing chain as follows:
    • Check that match mark on crank timing sprocket is in match with timing mark on lower crankcase.
    • Check that arrow mark on idler sprocket faces upward.
    • Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head.
    • Install second timing chain by aligning yellow plate of second timing chain and match marks on idler sprocket.
    • Install sprockets to intake and exhaust camshafts by aligning dark blue plate of second timing chain, match marks on intake sprocket and exhaust sprocket respectively. NOTE As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.



  • Install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary. Tighten the camshaft timing sprocket bolt to 57.5 ft. lbs. (80 Nm).
  • Push back plunger into tensioner body and hold it at the position by inserting stopper into body.
  • Install timing chain tensioner adjuster No.2 with new gasket. Tighten the timing chain tensioner adjuster No. 2 bolts to 8 ft. lbs. (11 Nm) and No. 2 nut to 33 ft. lbs. (45 Nm).
  • Pull out stopper from timing chain tensioner adjuster No.2.
  • Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block.
  • Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
  • Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
  • Install timing chain cover. Reverse removal sequence to install timing chain cover noting the following points:
    • Apply sealant "A" and "B" to area as shown.
      • "A": Sealant 99000-31250
      • "B": Sealant 99000-31140
    • Apply sealant amount to the following areas.
      • "a": 0.12 inches (3mm)
      • "b": 0.08 inches (2mm)
      • "c": 0.24 inches (6mm)
      • "d": 0.63 inches (16mm)
      • "e": 0.55 inches (14mm)
      • "f": 2.56 inches (65mm)
      • "g": 2.87 inches (73mm)
      • "h": 0.16 inches (4mm)
    • Apply engine oil to oil seal lip, then install timing chain cover. Tighten bolts and nut to 8 ft. lbs. (11 Nm).
      NOTE Before installing timing chain cover, check that pin is securely fitted.
    • Before installing timing chain cover, check that pin is securely fitted.
  • Install alternator belt idler pulley. Tighten nut to 30.5 ft. lbs. (42 Nm).
  • Install alternator belt tensioner. Tighten bolts to 18.5 ft. lbs. (25 Nm).
  • Install water pump pulley.
  • Install A/C compressor bracket (if equipped). Tighten bracket bolts to 40 ft. lbs. (55 Nm).
  • Install cylinder head cover with new gaskets and seal washers and tighten nuts to 8 ft. lbs. (11 Nm).
  • Install oil pan.
  • Install crankshaft pulley using pulley holder tool. Tighten the crankshaft pulley bolt to 108.5 ft. lbs. (150 Nm).
  • Install engine assembly.
  • Install all remaining components in the reverse order of the removal procedure.
did that cover it, surely not.
but if you get the FSM and read it or log in , you will not miss the photos and the complex sealing bs on this motor.
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Oct 18, 2014 • 2004 Suzuki Aerio
0helpful
1answer

Would like to have torque specs chart please?
Hi there, the following information are for a 2004 Grand Am 2.2L, I hope it helps:

--------------------------------------------------------------------------
Timing Chain, Sprockets, and/or Tensioner Replacement
--------------------------------------------------------------------------
Tighten the chain guide bolts to 10 N·m (89 lb in).
Tighten the chain tensioner bolts to 10 N·m (89 lb in).
Tighten the oil nozzle bolt to 10 N·m (89 lb in).
Timing chain tensioner guide bolt to 10 N·m (89 lb in).
Timing chain bolts to 10 N·m (89 lb in).
Chain guide plug to 90 N·m (66 lb ft).
Timing chain upper guide bolts to 10 N·m (89 lb in).
Timing chain tensioner to 75 N·m (55 lb ft).
Camshaft bolts to 85 N·m (63 lb ft) plus 30 degrees.
-------------------------------------------------------------------------
Intake Manifold Replacement
-------------------------------------------------------------------------
Manifold Nuts and Bolts: 10 N·m (89 lb in).
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Aug 30, 2014 • 2004 Pontiac Grand Am
0helpful
1answer

TIGHTEN THE CHAIN
Are you loosing the bar at the same time if yes then lift the bar up and then tighten the chain and then the bar there are some helpful video's on utube
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Jul 24, 2014 • Bosch Chainsaw Chain Saw Blade Ake 35...
0helpful
1answer

Its my first time tightening up kawasaki ninja chain
loosen main bolt. you must tighten side adjusters bolts (differ according to model/year) equally this is really important to handling.. a turn at a time is good. do it till the chain moves max 2 inches up and down in mid stream. then tighten, if you over tighten and then release you must make sure you push wheel back towards front of bike. oil chain regular esp in bad weather. your double the life with spray chain lube.
Read full answer
Feb 17, 2013 • Motorcycles
0helpful
1answer

I replaced the right side head on my 2001 mustang gt and i need to know how to set up the timming so it will run right
Hi, this engine user copper links on the chain align the copper links with the marks shown on the diagram below. Please let me know if you have more questions, and thanks for using FixYa.

To install:
  1. Compress the timing chain tensioner plunger in a soft jaw vise and install a retaining clip to hold the plunger in place.
  2. Remove the tensioner.
  3. If the copper links are not visible on the timing chains, mark one link on each end of the chain.
  4. Install the left and right timing chain guides and tighten the bolts to 89 inch lbs. (10 Nm).
  5. Position the lower end of the left timing chain on the crankshaft sprocket, aligning the copper link with the timing mark on the outer flange of the crankshaft sprocket.
  6. Position the timing chain on the left camshaft sprocket with the camshaft sprocket timing mark aligned with the copper link.
  7. Position the left timing chain tensioner arm on the dowel pin and install the timing chain tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
  8. Remove the retaining clip from the tensioner plunger.
  9. Position the lower end of the right timing chain on the crankshaft sprocket, aligning the copper link with the timing mark on the outer flange of the crankshaft sprocket.
  10. Position the timing chain on the right camshaft sprocket with the camshaft sprocket timing mark aligned with the copper link.
  11. Position the left timing chain tensioner arm on the dowel pin and install the timing chain tensioner. Tighten the bolts to 18 ft. lbs. (25 Nm).
  12. Remove the retaining clip from the tensioner plunger.
  13. Ensure correct alignment of all timing chain links and sprocket timing marks.
  14. Install the camshaft roller followers and tighten the camshaft sprocket bolts. See the procedure under Camshaft.
  15. Install the crankshaft sensor ring on the crankshaft.
    jturcotte_2085.gif

    Fig. Timing chain link and sprocket timing mark alignment-4.6L engine

  16. Apply sealant to the front cover mating surface as shown.
    jturcotte_2086.gif

    Fig. Sealant application to the front cover mating surface-4.6L engine

  17. Install a new gasket on the front cover, then install the front cover and hand tighten the bolts.
  18. Tighten the front cover bolts in the sequence shown to 18 ft. lbs. (25 Nm).
  19. Tighten the front cover-to-oil pan bolts in the sequence shown to 15 ft. lbs. (20 Nm), plus an additional 60 degrees
    jturcotte_2087.gif

    Fig. Front cover bolt tightening sequence-4.6L engine

    jturcotte_2088.gif

    Fig. Front cover-to-oil pan bolt tightening sequence-4.6L engine

  20. Lubricate the engine front cover and oil seal lip with clean engine oil and install the seal using a seal installer.
  21. Apply sealant to the Woodruff key slot in the crankshaft pulley, then press on the crankshaft damper.
  22. Tighten the crankshaft damper as follows:
    1. Step 1: 66 ft. lbs. (90 Nm).
    2. Step 2: Loosen the bolt one full turn.
    3. Step 3: 37 ft. lbs. (50 Nm).
    4. Step 4: 90 degrees.

  23. Connect the crankshaft position sensor connector.
  24. Install the power steering pump and tighten the bolts to 18 ft. lbs. (25 Nm).
  25. Install the wiring harness retainer to the power steering stud bolt.
  26. Install the power steering pump pulley shield.
  27. Install the water pump pulley.
  28. Install the J bracket to the engine front cover stud bolt.
  29. Install both left and right camshaft position sensor connectors.
  30. Install both left and right radio interference capacitors.
  31. Connect the hoses from the coolant crossover.
  32. Install the valve covers. See the procedure under Cylinder Head.
  33. Install the right side idler pulley.
  34. Install the accessory drive belt.
  35. Install the coolant degas bottle.
  36. Connect the negative battery cable.
  37. Fill the crankcase with clean engine oil.
  38. Start the engine. Check for leaks and proper operation.
Read full answer
Aug 14, 2011 • Ford Mustang Cars & Trucks
2helpful
1answer

2005 f250 5.4 gas need to know specs for timing a diagram would be awesome
To Install:
  1. Install balance shaft drive gear onto the left camshaft.
  2. Install the camshaft sprockets and new bolts finger tight.
  3. Using a vise, compress the timing chain tensioner plunger.

  4. Install a retaining clip on the tensioner to hold plunger IN during installation.
    marking timing chain a0038720.gif

  5. If timing chain copper links are not visible, mark 2 links on one end and 1 link on the other end to be used as timing marks.
  6. Install right and left timing chain guides. Tighten bolts to 89 in-lbs (10 Nm).
  7. Rotate the left camshaft until the timing mark is at the 12 o'clock position.
  8. Rotate the right camshaft until the timing mark is at the 11 o'clock position.

  9. Position the crankshaft using the special tool. Then remove the tool.
    Crankshaft special tool positioning n0013602.gif

  10. Install the crankshaft sprocket with flange facing forward.
    Crankshaft sprocket timing mark n0011528.gif

  11. Position lower end of left (inner) timing chain on the crankshaft sprocket. Align the copper (or marked) chain link with the timing mark on the outer flange of the crankshaft pulley. NOTE: Upper half of timing chain must be below the tensioner arm dowel.

  12. Position the left timing chain on the camshaft sprocket. The timing mark on the camshaft sprocket must be aligned between the 2 copper (or marked) chain links.
    Left camshaft sprocket timing mark a0080774.gif

  13. Place the left timing chain tensioner arm on the dowel pin and install the timing chain tensioner and bolts. Tighten bolts to 18 ft-lbs (25 Nm). NOTE: Lower half of timing chain must be above the tensioner arm dowel.
    Crankshaft sprocket timing mark a0079624.gif

  14. Position lower end of right (outer) timing chain on the crankshaft sprocket. Align the copper (or marked) chain link with the timing mark on the outer flange of the crankshaft pulley.
    Right camshaft sprocket timing mark a0041104.gif

  15. Position the right timing chain on the camshaft sprocket. The timing mark on the camshaft sprocket must be aligned between the 2 copper (or marked) chain links.
  16. Place the right timing chain tensioner arm on the dowel pin and install the timing chain tensioner and bolts. Tighten bolts to 18 ft-lbs (25 Nm).
  17. Remove the retaining clips from the right and left timing chain tensioners.
  18. Verify alignment of all timing marks.
  19. Install crankshaft sensor ring on crankshaft.
  20. Locate index mark on balance shaft and mark corresponding gear tooth with chalk.
  21. Position balance shaft on journals. NOTE: It may be helpful to use an inspection mirror to view the marks timing marks.

  22. Align the chalk mark on the balance shaft with the camshaft timing mark.
    Balance shaft bearing caps n0007112.gif

  23. Install the balance shaft bearing caps in their original locations. Follow the tightening sequence as shown in the illustration. Tighten bolts to 89 in-lbs (10 Nm).
  24. Tighten the camshaft phaser sprocket bolts in the correct sequence using 2 steps, as follows:
    • Step 1-30 ft-lbs (40 Nm)
    • Step 2-tighten an additional 90 degrees
  25. Position the crankshaft keyway in the 11 o'clock position.
  26. Lubricate and install all camshaft roller followers. WARNING
    Engine front cover replacement procedure must be completed within 4 minutes or entire procedure must be repeated. Failure to do so may result in future leaks
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Oct 07, 2010 • Ford F-250 Cars & Trucks
0helpful
1answer

How to tighten the chain on my saw?
Depending on the type of chain saw.....there should be a nut near the bar on the housing which by turning it you should be able to loosen and tighten the chain; sometimes the bar can be slid forward which tightens the chain. Depending on the age of the chain saw it might be time for a new one!
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Aug 25, 2009 • Garden
4helpful
1answer

Need to tighten the timing chain
It has an automatic cam chain tensioner. If you are getting cam chain rattle, I would look at worn guides/chain.
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Jul 22, 2009 • 1996 Honda VT 1100 C2 Shadow Sabre
2helpful
2answers

Timing on 4.7 help
INSTALLATION
  1. Using a vise, lightly compress the secondary chain tensioner piston until the piston step is flush with the tensioner body. Using a pin or suitable tool, release ratchet pawl by pulling pawl back against spring force through access hole on side of tensioner. While continuing to hold pawl back, Push ratchet device to approximately 2 mm from the tensioner body. Install Special Tool 8514 lock pin into hole on front of tensioner. Slowly open vise to transfer piston spring force to lock pin (Resetting Secondary Chain Tensioners).
  2. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 28 N·m (250 in. lbs.). CAUTION: Overtightening the tensioner arm torx® bolt can cause severe damage to the cylinder head. Tighten torx® bolt to specified torque only.
  3. Install right side chain tensioner arm. Apply Mopar® Lock N, Seal to torx® bolt, tighten bolt to 17 N·m (150 in. lbs.). NOTE: The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
  4. Install the left side chain guide. Tighten the bolts to 28 N·m (250 in. lbs.). CAUTION: Overtightening the tensioner arm torx® bolt can cause severe damage to the cylinder head. Tighten torx® bolt to specified torque only.
  5. Install left side chain tensioner arm. Apply Mopar® Lock N, Seal to torx® bolt, tighten bolt to 17 N·m (150 in. lbs.).
  6. Install the right side chain guide. Tighten the bolts to 28 N·m (250 in. lbs.).
  7. Install both secondary chains onto the idler sprocket. Align two plated links on the secondary chains to be visible through the two lower openings on the idler sprocket (4 o'clock and 8 o'clock). Once the secondary timing chains are installed, position special tool 8515 to hold chains in place for installation (Installing Secondary Timing Chains on Idler Sprocket).
  8. Align primary chain double plated links with the timing mark at 12 o'clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o'clock on the crankshaft sprocket (Timing Chain System).
  9. Lubricate idler shaft and bushings with clean engine oil.
  10. Install all chains, crankshaft sprocket, and idler sprocket as an assembly (Installing Idler Gear, Primary and Secondary Timing Chains). After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or the equivalent, This will maintain tension on chains to aid in installation. NOTE: It will be necessary to slightly rotate camshafts for sprocket installation.
  11. Align left camshaft sprocket “L” dot to plated link on chain.
  12. Align right camshaft sprocket “R” dot to plated link on chain. CAUTION: Remove excess oil from the camshaft sprocket bolt. Failure to do so can result in over-torque of bolt resulting in bolt failure.
  13. Remove Special Tool 8515, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
  14. Verify that all plated links are aligned with the marks on all sprockets and the “V8” marks on camshaft sprockets are at the 12 o'clock position (Timing Chain System). CAUTION: Ensure the plate between the left secondary chain tensioner and block is correctly installed.
  15. Install both secondary chain tensioners. Tighten bolts to 28 N·m (250 in. lbs.). NOTE: Left and right secondary chain tensioners are not common.
  16. Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 34 N·m (25 ft. lbs.).
  17. Remove all locking pins (3) from tensioners. CAUTION: After pulling locking pins out of each tensioner, DO NOT manually extend the tensioner(s) ratchet. Doing so will over tension the chains, resulting in noise and/or high timing chain loads.
  18. Using Special Tool 6958, Spanner with Adaptor Pins 8346, tighten left (Tightening Left Side Camshaft Sprocket Bolt) and right (Tightening Right Side Camshaft Sprocket Bolt). camshaft sprocket bolts to 122 N·m (90 ft. lbs.).
  19. Rotate engine two full revolutions. Verify timing marks are at the follow locations:
  20. Lubricate all three chains with engine oil.
  21. After installing all chains, it is recommended that the idler gear end play be checked (Measuring Idler Gear End Play). The end play must be within 0.10–0.25 mm (0.004–0.010 in.). If not within specification, the idler gear must be replaced.
  22. Install timing chain cover (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION) and crankshaft damper (Refer to 9 - ENGINE/ENGINE BLOCK/VIBRATION DAMPER - INSTALLATION).
  23. Install cylinder head covers (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - INSTALLATION). NOTE: Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.
  24. Coat the large threaded access plug with Mopar® Thread Sealant with Teflon, then install into the right cylinder head and tighten to 81 N·m (60 ft. lbs.) (Cylinder Head Access Plug Location).
  25. Install the oil fill housing.
  26. Install access plug in left cylinder head (Cylinder Head Access Plug Location).
  27. Install power steering pump (Refer to 19 - STEERING/PUMP - INSTALLATION).
  28. Install radiator fan shroud.
  29. Fill cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).
  30. Connect negative cable to battery.
Read full answer
Jul 08, 2009 • 2000 Dodge Durango
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