How to install timing chain tensioner

TDC related to piston one and should be as such.

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.
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.
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.

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.

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).


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.
    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).

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.

Hi Josiah:
According with the repair guide...4.0L Engine

1. Before servicing the vehicle, refer to the Precautions section.
   
2. Drain the engine oil.
   
3. Remove or disconnect the following:
   Negative battery cable Engine from the vehicle Oil pan Engine front cover Cylinder heads
4. Lock the jackshaft tensioner by installing a pin.
   Jackshaft sprocket and chain assembly Left front cassette retaining bolt Cassette chain and tensioner assembly Rear jackshaft plug from the engine Right rear cassette retaining bolt and spacer Right rear cassette chain and tensioner Timing chain (s)
   
   

Fig. Remove the jackshaft sprocket-4.0L SOHC Engine 2000-2001
Zooming link for Remove the jackshaft sprocket-4.0L SOHC Engine 2000-2001

To install:

1. Install or connect the following:
   Timing chain(s) Right rear cassette chain, tensioner and sprocket Jackshaft sprocket and chain on the engine and remove the tensioner pin
   
2. Torque the jackshaft sprocket bolt in 2 stages:
   1. 32-35 ft. lbs. (43-47 Nm).
      
   2. Turn an additional 65 degrees.
      
3. Install or connect the following:
   Cylinder heads Front cover Oil pan Engine to the vehicle Negative battery cable
4. Fill the engine with clean oil.
   
5. Start the vehicle, check for leaks and repair if necessary.

1. Before servicing the vehicle, refer to the Precautions section.
   
2. With the vehicle in neutral, position it on a hoist.
   
3. Remove the intake manifold.
   
4. Remove the fuel supply manifold.
   
5. Remove the accessory drive belt.
   
6. Remove the thermostat housing.
   
7. Remove the roller followers.
   NOTE You must retime the LH and RH camshafts when either camshaft is disturbed. Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).
   
   NOTE The special tool must be installed on the damper and should contact the engine block to position the engine at TDC.
   
8. Install the special tool.
   NOTE The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
   NOTE If necessary, use camshaft gear torque adapter to loosen the camshaft sprocket bolt.

Hope this helps; also keep in mind that your feedback is important and I`ll appreciate your time and consideration if you leave some testimonial comment about this answer.

Thank you for using FixYa, have a nice day.

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.

1998-2003 To Remove:

1. Remove or disconnect the following:
   • Crankshaft pulley and hub
   • Drive belt tensioner
     
     
   • Timing chain cover bolts
     
     
   • Timing chain cover and gasket
2. Install a bolt in the end of the crankshaft CAUTION
   Do not install the crankshaft balancer bolt or a bolt longer than 1 inch or damage to the crankshaft threaded hole will result.
   
3. Rotate crankshaft until the number 1 piston is at Top Dead Center of compression stroke.
4. Make sure that the alignment marks are aligned with the tabs on the timing chain tensioner.
   
   
5. Measure distance between hole in bracket and unworn surface of timing chain tensioner shoe. NOTE: If distance between the hole and unworn surface of timing chain tensioner is greater than 0.314 in (8 mm), replace tensioner, timing chain and sprockets.
   
6. Remove timing chain tensioner bolts.
7. Remove the timing chain, timing chain tensioner and camshaft sprocket at the same time.
8. Remove the crankshaft sprocket using special tool J 22888-20A or equivalent.
9. Remove crankshaft sprocket alignment key.

NOTE: If any camshaft components are being replaced to correct a noise problem, all camshaft drive components must be replaced.
To Install:

1. Install the crankshaft sprocket alignment key.
2. Install the crankshaft sprocket using special tool J 5590 or equivalent.
   
   
3. Compress the timing chain tensioner spring and insert a pin into the tensioner hole to retain the tensioner shoe.
4. Install timing chain and timing chain tensioner (do not tighten tension bolts).
5. Align the crankshaft and camshaft timing marks with the tab on the timing chain tensioner.
6. Tighten the timing chain tensioner bolts.
   • Torque to: 18 ft lbs (24 Nm)
7. Tighten the camshaft sprocket bolt.
   • Torque to: 96 ft lbs (130 Nm)
8. Remove pin from timing chain tensioner hole.
9. Remove bolt from end of crankshaft. CAUTION
   Inspect the timing chain cover for warping or damage. Replace if needed.
   
10. Clean all timing chain cover mating surfaces.
11. Install or connect the following:
    • Timing chain cover to the engine block
      1. Ensure that the gasket is installed properly in the groove in the timing chain cover
    • Timing chain cover and make sure it fully seated on the alignment dowel pins
    • Timing chain cover bolts
      1. Torque to: 97 inch lbs (11 Nm)
    • Drive belt tensioner
    • Crankshaft damper hub and the crankshaft pulley

Except Premier
Procedures applying to removal and installation of the auxiliary shaft drive chains are located under Auxiliary (Intermediate or Silent) Shafts Removal and Installation, later in this section.
2.5L Premier Engine (See Figures 1 through 5)

Fig. 1: To remove the timing chain, remove the timing chain case cover

Fig. 2: When removing and installing the timing chain the crankshaft and camshaft sprocket timing marks should be aligned as shown

Fig. 3: While holding the timing chain, camshaft sprocket and crankshaft sprocket aligned install them onto the engine


Fig. 4: Lock and unlock the timing chain tensioner by switching the tensioner lever, as shown


Fig. 5: To verify correct installation, turn the crankshaft until the camshaft sprocket timing mark is approximately at the one o'clock position, then count the number of chain link pins between the points shown

1. Disconnect the negative battery cable.
2. Remove the fan shroud and cooling fan, as described earlier in this section.
3. Remove the accessory drive belts. For more information, refer to .
4. Remove the water pump pulley and crankshaft vibration damper, as described earlier in this section.
5. Remove the timing case cover, as described previously in this section.

It is a good practice to either remove or cover the radiator area when performing extensive repairs to the engine to prevent accidental damage to the radiator core.

1. Rotate the crankshaft until the 0 timing mark on the crankshaft sprocket is closest to and on a center line with the timing mark on the camshaft sprocket.
2. Remove the oil slinger from the crankshaft.
3. Remove the camshaft retaining bolt and remove the sprockets and chain as an assembly.
4. If the timing chain tensioner is to be replaced, the oil pan must also be removed.

To install:

1. Turn the tensioner lever to the unlock (down) position and pull the tensioner block toward the tensioner lever to compress the spring. Hold the block and turn the tensioner lever to the lock (up) position.
2. Install the crankshaft sprocket, camshaft sprocket and timing chain together. Make sure the timing marks are aligned as indicated in Step 6 and in the accompanying illustration.
3. Install the camshaft sprocket retaining bolt and washer. Tighten the bolt to 80 ft. lbs. (108 Nm).
4. To verify correct installation of the timing chain, rotate the crankshaft until the camshaft sprocket timing mark is approximately at the 1 o'clock position. Count the number of chain link pins between the camshaft timing mark and the crankshaft timing mark, there should be 20 pins (2 per link) between the marks.
5. Make sure that the timing chain tensioner switches to the unlocked position. If the tensioner does not switch automatically unlock, switch it manually to the unlock position.
6. Install the oil slinger.
7. Install the timing case cover, as described earlier in this section.
8. Install the water pump pulley and crankshaft vibration damper, as described earlier in this section.
9. Install and properly tension the accessory drive belts. For more information, refer to .
10. Install the fan shroud and cooling fan, as described earlier in this section.
11. Connect the negative battery cable, start the engine and check for leaks.

Good luck... and remember rated this 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:
    • primary chain idler sprocket dot is at 12 o'clock (Timing Chain System)
    • primary chain crankshaft sprocket dot is at 6 o'clock (Timing Chain System)
    • secondary chain camshaft sprockets “V8” marks are at 12 o'clock (Timing Chain System)
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.

I'm not sure what you may be "doing wrong", but here is the manufacturer procedure for aligning the timing marks.


^Refer to this diagram during step 12.

^Refer to this diagram during step 13.

^Refer to this diagram for step 19.

1. Align crankshaft sprocket timing mark to the mark on oil pump housing. NOTE: Lubricate timing chain and guides with engine oil before installation.
2. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links.
3. 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.
4. Loosely position left side camshaft sprocket over camshaft hub.
5. Align timing (plated) link to the crankshaft sprocket timing mark.
6. Position primary chain onto water pump drive sprocket.
7. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain and loosely position over camshaft hub.
8. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
9. Install left side lower chain guide and tensioner arm. Tighten attaching bolts to 28 Nm (250 in. lbs.). NOTE: Inspect oil ring on chain guide access plug before installing. Replace O-ring as necessary.
10. Install chain guide access plug to left side cylinder head. Tighten plug to 20 Nm (15 ft. lbs.)
11. NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.
12. Purge oil from timing chain tensioner using the following procedure:
a) Place the check ball end of tensioner into the shallow end of Special Tool 8186.
b) Using hand pressure, slowly depress tensioner until oil is purged from tensioner.
13. Reset timing chain tensioner using the following procedure:
a) Position cylinder plunger into the deeper end of Special Tool 8186.
b) 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 must bottom against the top edge of Special Tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.
14. Install the reset chain tensioner into the right cylinder head.
15. Position tensioner retaining plate and tighten bolts to 12 Nm (105 in. lbs.).
16. Starting at the right cylinder bank, 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 in. lbs.).
17. 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 in. lbs.).
18. Rotate engine slightly clockwise to remove timing chain slack, if necessary.
19. To arm the timing chain tensioner: Use a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then, release the tensioner arm. Verify the tensioner is armed (extends).
20. Install the timing chain cover, crankshaft damper, and cylinder head covers.
21. Install camshaft position sensor and connect electrical connector.

Hope this helps!
Mitchell