ENGINE MECHANICAL COMPONENTS:

1.17 Timing Chain & Sprockets

Removal & Installation

2.7L Engine

Before servicing the vehicle, refer to the Precautions section.

Disconnect negative battery cable.

Drain cooling system.

Remove upper intake manifold.

Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.
WARNING
When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in
valve and/or piston damage.

Fig. Align crankshaft sprocket timing mark to mark on oil pump housing. The mark on oil pump housing is
60° ATDC of no.1 cylinder-2.7L engine

Align crankshaft sprocket timing mark to mark on oil pump housing. The mark on oil pump housing is 60°
ATDC of no.1 cylinder.
WARNING
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.

Click to enlarge

Fig. Primary timing chain tensioner removal-2.7L engine

Remove primary timing chain tensioner retainer cap and tensioner from right cylinder head.

Fig. Timing chain and related parts-2.7L engine

Disconnect and remove camshaft position sensor (4) from left cylinder head.

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

To install:

Click to enlarge

Fig. Timing chain installation-2.7L engine

Inspect all sprockets (4, 9, and 11) and chain guides (2, 5,and 10). Replace if worn.
 
Install crankshaft sprocket.
 
If removed, install right and left side short chain guides (10). Tighten attaching bolts to 21 ft. lbs. (28 Nm).
 
Align crankshaft sprocket timing mark to the mark on oil pump housing (3).
NOTE
Lubricate timing chain and guides with engine oil before installation.

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

 
Loosely position left side camshaft sprocket over camshaft hub.
 
Align timing (plated) link to the crankshaft sprocket timing mark (3).
 
Position primary chain onto water pump drive sprocket (11).
 
Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely
position over camshaft hub.
 
Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
 
Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 21 ft. lbs. (28 Nm).
NOTE
Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

 
Install chain guide access plugs to cylinder heads. Tighten plugs to15 ft. lbs. (20 Nm).
NOTE
To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

Click to enlarge

Fig. Purging oil from the tensioner-2.7L engine

 
Purge oil from timing chain tensioner using the following procedure:
Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
 
 Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

Click to enlarge

Fig. Reset the tensioner-2.7L engine

 

 
Reset timing chain tensioner using the following procedure:
Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
 
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 tensioners check ball.

WARNING
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 snapring (1) is correctly installed,
replace as necessary.

 
Install the reset chain tensioner into the right cylinder head.
 
Position tensioner retaining plate and tighten bolts to 105 inch lbs. (12 Nm).
 
Starting at the right cylinder bank, first position the camshaft damper (if equipped) on camshaft hub, then
insert a
3
/
8
in. 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 21 ft. lbs. (28 Nm).
 
Turn the left side camshaft by inserting a
3
/
8
in. 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 21 ft. lbs. (28 Nm).
 
Rotate engine slightly clockwise to remove timing chain slack, if necessary.

Click to enlarge

Fig. 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)-2.7L engine
 
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).
 
Install camshaft position sensor and connect electrical connector.
 
Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
 
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.

 
Fill cooling system.
 
Connect negative battery cable.
 

Crankshaft Sprocket
 Before servicing the vehicle, refer to the Precautions section.
 
Remove primary timing chain.
WARNING
Use care not to turn crankshaft while removing crankshaft sprocket, as damage to valves and or pistons
could occur.

 
Remove crankshaft sprocket by first installing the crankshaft damper bolt. Apply grease or equivalent to
damper bolt head and position Special Tools 5048-1(3), 5048-6 (2), and 8539 (1) on sprocket and
crankshaft nose. Remove sprocket using care not to rotate the crankshaft.

Click to enlarge

Fig. Crankshaft sprocket removal-2.7L engine

 

To install:

Click to enlarge
Fig. Crankshaft sprocket installation-2.7L engine

Install crankshaft sprocket using Special Tools 6780-1(1) and 8179 (2) until sprocket bottoms against
crankshaft step flange. Use care not to rotate crankshaft.
 
Verify that crankshaft sprocket is installed to proper depth by measuring from sprocket outer face to end of
crankshaft. Measurement should read: 39.05 ± 0.50 mm (1.5374 ± 0.020 in.).
 
Install primary timing chain.
 

5.7L Engine

Before servicing the vehicle, refer to the Precautions section.

 
Disconnect negative battery cable.
 
Drain cooling system.
 
Remove timing chain cover.
 
Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the
crankshaft to align timing chain sprockets and keyways as shown.
WARNING
The camshaft pin and the slot in the cam sprocket must be positioned at 12:00 (2). The crankshaft keyway
must be positioned at 2:00 (3). The crankshaft sprocket must be installed so that the dots and or paint
marking is at 6:00.

Click to enlarge

Fig. Timing mark alignment-5.7L engine

 Click to enlarge

Fig. Retract tensioner shoe (1) until hole in shoe lines up with hole in bracket. Slide a suitable pin (2) into the
holes-5.7L engine
 
Retract tensioner shoe until hole in shoe lines up with hole in bracket.
 
Slide a suitable pin into the holes.
 
Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
 
If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly.
 

To install:

If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 21 ft. lbs. (28
Nm).
 
Retract tensioner if required.
WARNING
The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the
camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket
between two plated timing chain links.

WARNING
The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be
clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.

 
Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary
center line through both camshaft and crankshaft bores.
 
Place timing chain around both sprockets.
  
Lift sprockets and chain. Keep sprockets tight against the chain.
 
Slide both sprockets evenly over their respective shafts and check alignment of timing marks.
 
Install the camshaft bolt. Tighten the bolt to 90 ft. lbs. (122 Nm).
 
Remove tensioner pin. Again, verify alignment of timing marks.
 
Install the oil pump.
 
Install the oil pan and pick up.
 
Install the timing chain cover
 
Refill engine oil.
 
Fill cooling system.
 
Connect negative battery cable.
 
Start engine and check for oil and coolant leaks.
 

ENGINE
MECHANICAL
ENGINE MECHANICAL COMPONENTS Change Chapter

1.17 Tim ing Chain & Sprockets

Removal & Installation

2.7L Engine

Before servicing the vehicle, refer to the Precautions section.

 
Disconnect negative battery cable.
 
Drain cooling system.
 
Remove upper intake manifold.
 
Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.
WARNING
When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve
and/or piston damage.

Pinch to zoom

Fig. Align crankshaft sprocket timing mark to mark on oil pump housing. The mark on oil pump housing is 60° ATDC
of no.1 cylinder-2.7L engine
 
Align crankshaft sprocket timing mark to mark on oil pump housing. The mark on oil pump housing is 60° ATDC of
no.1 cylinder.
WARNING
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.

Pinch to zoom

Fig. Primary timing chain tensioner removal-2.7L engine

 
Remove primary timing chain tensioner retainer cap and tensioner from right cylinder head.

Pinch to zoom

Fig. Timing chain and related parts-2.7L engine

 
Disconnect and remove camshaft position sensor (4) from left cylinder head.
 
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.

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

To install:

Pinch to zoom

Fig. Timing chain installation-2.7L engine

Inspect all sprockets (4, 9, and 11) and chain guides (2, 5,and 10). Replace if worn.
 
Install crankshaft sprocket.
 
If removed, install right and left side short chain guides (10). Tighten attaching bolts to 21 ft. lbs. (28 Nm).
 
Align crankshaft sprocket timing mark to the mark on oil pump housing (3).
NOTE
Lubricate timing chain and guides with engine oil before installation.

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

 
Loosely position left side camshaft sprocket over camshaft hub.
 
Align timing (plated) link to the crankshaft sprocket timing mark (3).
 
Position primary chain onto water pump drive sprocket (11).
 
Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely position over
camshaft hub.
 
Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
 
Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 21 ft. lbs. (28 Nm).
NOTE
Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

 
Install chain guide access plugs to cylinder heads. Tighten plugs to15 ft. lbs. (20 Nm).
NOTE
To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.
 Pinch to zoom

Fig. Purging oil from the tensioner-2.7L engine

 
Purge oil from timing chain tensioner using the following procedure:
Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
 
Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

Pinch to zoom

Fig. Reset the tensioner-2.7L engine

 

 
Reset timing chain tensioner using the following procedure:
Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
 
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 tensioners check ball.

WARNING
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 snapring (1) is correctly installed, replace
as necessary.

 
Install the reset chain tensioner into the right cylinder head.
 
Position tensioner retaining plate and tighten bolts to 105 inch lbs. (12 Nm).
 
Starting at the right cylinder bank, first position the camshaft damper (if equipped) on camshaft hub, then insert a
3
/
8
in. 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 21 ft. lbs. (28 Nm).
 
 Turn the left side camshaft by inserting a
3
/
8
in. 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 21 ft. lbs.
(28 Nm).
 
Rotate engine slightly clockwise to remove timing chain slack, if necessary.

Pinch to zoom

Fig. 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)-2.7L engine
 
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).
 
Install camshaft position sensor and connect electrical connector.
 
Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
 
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.

 
Fill cooling system.
 
Connect negative battery cable.
 

Crankshaft Sprocket

Before servicing the vehicle, refer to the Precautions section.

 
Remove primary timing chain.
WARNING
Use care not to turn crankshaft while removing crankshaft sprocket, as damage to valves and or pistons could
occur.

 
Remove crankshaft sprocket by first installing the crankshaft damper bolt. Apply grease or equivalent to damper
bolt head and position Special Tools 5048-1(3), 5048-6 (2), and 8539 (1) on sprocket and crankshaft nose.
Remove sprocket using care not to rotate the crankshaft.

Pinch to zoom

Fig. Crankshaft sprocket removal-2.7L engine

 
To install:

Pinch to zoom

Fig. Crankshaft sprocket installation-2.7L engine

Install crankshaft sprocket using Special Tools 6780-1(1) and 8179 (2) until sprocket bottoms against crankshaft
step flange. Use care not to rotate crankshaft.
 
Verify that crankshaft sprocket is installed to proper depth by measuring from sprocket outer face to end of
crankshaft. Measurement should read: 39.05 ± 0.50 mm (1.5374 ± 0.020 in.).
 
Install primary timing chain.
 

5.7L Engine

Before servicing the vehicle, refer to the Precautions section.

 
Disconnect negative battery cable.
 
Drain cooling system.
 
Remove timing chain cover.
 
Re-install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to
align timing chain sprockets and keyways as shown.
WARNING
The camshaft pin and the slot in the cam sprocket must be positioned at 12:00 (2). The crankshaft keyway must be
positioned at 2:00 (3). The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.

Pinch to zoom

Fig. Timing mark alignment-5.7L engine

Pinch to zoom

Fig. Retract tensioner shoe (1) until hole in shoe lines up with hole in bracket. Slide a suitable pin (2) into the holes-
5.7L engine
 
Retract tensioner shoe until hole in shoe lines up with hole in bracket.
 
Slide a suitable pin into the holes.
 
Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets.
  
If tensioner assembly is to be replaced, remove the tensioner to block bolts and remove tensioner assembly.
 

To install:

If tensioner assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 21 ft. lbs. (28 Nm).
 
Retract tensioner if required.
WARNING
The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the
camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between
two plated timing chain links.

WARNING
The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be
clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.

 
Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center
line through both camshaft and crankshaft bores.
 
Place timing chain around both sprockets.
 
Lift sprockets and chain. Keep sprockets tight against the chain.
 
Slide both sprockets evenly over their respective shafts and check alignment of timing marks.
 
Install the camshaft bolt. Tighten the bolt to 90 ft. lbs. (122 Nm).
 
Remove tensioner pin. Again, verify alignment of timing marks.
 
Install the oil pump.
 
Install the oil pan and pick up.
 
Install the timing chain cover
 
Refill engine oil.
 
Fill cooling system.
 
Connect negative battery cable.
 
Start engine and check for oil and coolant leaks.