Pontiac Grand Prix 3.8L Engine Timing Chain Replacement

How To Replace Pontiac Timing Chain

Before Getting With 3.8L Engine Timing Chain Replacement Procedure Its Advisable To Refer Timing Chain Replacing Procedure For Other Engine Models Too.

For Pontiac Timing Chain Replacing Procedure Click Here:


For 3.8l Engine Timing Chain Replacing The Procedure Is As Follows:

3.8L Engine

Fig. Exploded view of lower engine components-3.8L engine

1. Drain the coolant system.
2. Drain the engine oil.
3. Install an Engine Support Fixture.
4. Raise the engine so that the weight is removed from the engine mount.
5. Remove or disconnect the following:

• Negative battery cable
• Water pump pulley bolts
• Accessory drive belt(s)
• Drive belt tensioner
• Water pump pulley
• Crankshaft balancer
• Crankshaft Position (CKP) and Camshaft Position (CMP) sensor connections
• Oil pressure sensor connection
• CKP sensor shield
• Engine mount bracket
• Front oil pan-to-front cover bolts
• Oil filter
• Lower radiator hose
• CKP sensor
• Front cover

Rotate the crankshaft until the timing mark on the camshaft sprocket is aligned with the crankshaft sprocket timing mark

Timing chain damper assembly

Camshaft sprocket bolt

Camshaft sprocket with the timing chain

Crankshaft sprocket

To install:

Fig. Exploded view of the timing chain and sprockets-3.8L engines

Fig. Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment-3.8L engine

Camshaft,Crankshaft Alignment Marks

1. Install the crankshaft sprocket.
   
   NOTE

   It may be necessary to use a gear installer to fully seat the gear. Be sure the timing mark on the crankshaft gear is pointing straight up.
2. Install the camshaft gear with the timing chain.
   
   NOTE

   Hold the sprocket with the timing mark facing downward and the chain hanging down off the sprocket; then, loop the chain under the crankshaft sprocket.
3. If the marks are not in alignment perform the following:
   1. Step 1: Remove the camshaft sprocket and timing chain.
   2. Step 2: Install the camshaft sprocket onto the camshaft and rotate the camshaft until the camshaft and crankshaft marks are aligned.
   3. Step 3: Remove the camshaft sprocket.
   4. Step 4: Reinstall the assembly.
4. Install or connect the following:
   
   
   Camshaft sprocket bolt and torque the bolt to 74 ft. lbs. (100 Nm) plus an additional 90 degree turn
   

   Timing chain damper and torque the mounting bolts to 16 ft. lbs. (22 Nm)
   

   Front cover seal lubricated with engine oil, using the appropriate seal driver
   

   New front cover gasket
   

   Front cover and torque the bolts to 15 ft. lbs. (20 Nm) plus an additional 40 degree turn
   

   Oil pan-to-front cover bolts and torque the bolts to 125 inch lbs. (14 Nm)
   

   CKP sensor and torque the bolts to 21 ft. lbs. (28 Nm)
   

   CKP sensor shield
   

   Engine mount bracket and torque the bolts to 65 ft. lbs. (87 Nm)
   

   Water pump pulley and torque the bolts to 115 inch lbs. (13 Nm)
   

   Lower radiator hose
   

   Oil filter
   

   Crankshaft balancer and torque the bolt to 111 ft. lbs. (150 Nm) plus an additional 75 degree turn
   

   Belt tensioner and torque the bolts to 37 ft. lbs. (50 Nm)
   

   Accessory drive belt
   

   Negative battery cable
   
5. Remove the engine support fixture.
6. Refill the cooling system.
7. Refill the engine oil.
8. Start the engine and check for leaks, repair if necessary.

For 5.3 engine Timing Chain Replacement click this link below:----

http://technoanswers.blogspot.com/2011/02/2004-pontiac-grand-prix-timing-chain.html

Pontiac grand Prix timing chain Installation Procedure

How To Install Timing Chain On Pontiac

Before going through timing chain installation procedure its suggested to view timing chain removal procedure.

For Timing Chain Removal Procedure Please Click Here 

Pontiac Timing Chain Installation Procedure:

To install:
Install or connect the following:

NOTE
Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.

Timing chain damper (if removed) and torque the bolts to 15 ft. lbs. (21 Nm)
Crankshaft sprocket


Timing chain over the camshaft sprocket

Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft.
Verify that the marks are aligned; the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position.

NOTE
The No. 1 piston will be at Top Dead Center (TDC) and the No. 4 piston will also be at TDC but on the compression stroke.

Tighten the camshaft sprocket bolt to 103 ft. lbs. (140 Nm).
Lubricate the timing chain components with engine oil.

Install or connect the following:

• New front cover seal
• Front cover using a new gasket and torque the small bolts to 20 ft. lbs. (27 Nm) and the large bolts to 41 ft. lbs. (55 Nm)
• Water pump pulley and torque the bolts to 18 ft. lbs. (25 Nm)
• Upper radiator hose
• Thermostat bypass pipe
• Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
• Drive belt tensioner and torque the bolt to 37 ft. lbs. (50 Nm)
• CKP sensor
• Crankshaft balancer and torque the bolt to 76 ft. lbs. (103 Nm)
• Accessory drive belt
• Coolant reservoir
• Negative battery cable

Refill the fluids.
Start the engine and check for leaks, repair if necessary.


Its Suggested To Go through Chain Tensioner details for Further help.

For Primary Chain and Secondary Chain Tensioner Adjustment and details Click Here

2005 Dodge Durango: Replace Camshaft position sensor and Crankshaft Position Sensor?

How to replace Camshaft Position sensor on Dodge Durango.
And how to replace Crankshaft position Sensor on Dodge Durango.

The Procedure to replace both Sensors with details and helpful diagram is as follows:---------


The Camshaft Position Sensor (CMP) on the 5.7L V-8 engine is located below the
generator on the timing chain / case cover on the right/front side of
engine.

Well, there is enough room to get to the sensor without removing the Alternator, however, sometimes the sensor is a little tough to remove due to time, build-up, etc taking its toll on the rubber o-ring. So, to get better leverage, and a better grip on the sensor to remove it, you may need to remove the Alternator.



See the diagram shown below:-------




Crankshaft sensor is a straight shot. best access is from under the vehicle working upwards. Same deal with the rubber o-ring, though. It sometimes can be a little tough to remove. With both sensors, when installing the new sensor, lube the new o-ring a little bit for easier installation.


The Crankshaft Position (CKP) Sensor is mounted into the right rear side
of the cylinder block. It is positioned and bolted into a machined hole. Best access is from under the vehicle, working upwards.

See the help diagram shown below:----------




This details will help.
Thanks.

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Removal & Installation

M62 4.4L Engines

Fig. Gap in increment gear must fit in tool No. 11-3-440-M62 4.4L engines

Fig. Left side camshaft identification (cylinder bank 5 to 8): hex head (3) on intake camshaft between cylinders 7 and 8, hex head (4) on exhaust camshaft between cylinders 5 and 6-M62 4.4L engines

Fig. Right side camshaft identification (cylinder bank 1 to 4): hex-head (2) on intake camshaft between cylinders 3 and 4, hex-head (1) on exhaust camshaft between cylinders 1 and 2-M62 4.4L engines

Fig. Camshaft positioning-M62 4.4L engines

Fig. Install left-hand camshafts: Recesses in camshaft point downwards approximately 30-40 degrees from plane of cylinder head-M62 4.4L engines

Fig. Install right-hand camshafts: Recesses in camshaft point upward approximately 30-40 degrees from plane of cylinder head-M62 4.4L engines

Left Camshaft (Cylinder Bank 5-8)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Left and right cylinder head covers

   Spark plugs

   Top left timing case cover

   Splash guard

   Oil lines to the left and right cylinder head
   
   
3. Rotate the crankshaft in direction of rotation until cylinder number 1 is in TDC firing position.
4. Brace the camshaft on the hex head with a suitable open-end wrench and loosen the 3 accessible fasteners on the right sprocket approximately ¹ / ₂ a turn.
   1. Turn the engine over once and loosen the remaining 3 fasteners on each right sprocket approximately ¹ / ₂ a turn.
   2. Remove the primary sprocket from the left-hand intake camshaft (cylinder bank 5-8). Secure the chain to prevent it from dropping into the engine.

   
   
5. Rotate the engine to 45 degrees BTDC. Rotate the crankshaft against direction of rotation until the gap in the increment gear fits in tool No. 11-3-440.
6. Remove or disconnect the following:
   
   
   Fasteners on the exhaust camshaft

   Fasteners on the exhaust camshaft sprocket. Do not remove the sprocket.
   
   
7. Compress the chain tensioner and install tool No. 11-3-420 to lock the tensioner in place.
8. Lift off both secondary camshaft sprockets together with the chain.
9. Rotate the intake and exhaust camshafts to the installed position as follows:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees downwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
10. Loosen the both camshaft bearing caps uniformly from outside to inside¹ / ₂ turn.
11. Remove or disconnect the following:
    
    
    All bearing caps. Label each bearing cap to facilitate reassembly and place aside.

    Camshafts noting their locations

    Hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring.
    
    

To install:

1. If the lifters were removed, install them with tool No. 11-32-250.
2. Lubricate and install the camshafts in their correct position.
   
   NOTE

   The intake camshaft will have a hexagon between cylinders 7 and 8. The exhaust camshaft will have the hexagon between cylinders 5 and 6.
   
   
3. Rotate the intake and exhaust camshafts to the installed position as follows:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees downwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
4. Install the bearing caps, tightened from outside to inside in 1/2 turn increments to 9-13 ft. lbs. (12-17 Nm).
   
   NOTE

   Do not confuse camshaft bearing caps of cylinders No. 1-4 and 5-8. The exhaust camshaft bearing caps are marked A1 through A5. The intake camshaft bearing caps are marked E1 through E5 from intake end.
   
   
5. Fit tool No. 11-3-430 to the camshaft. Rotate the camshaft until the marker bores face upwards.
6. Install tool Nos. 11-2-442/446 to the camshaft on cylinder bank 5-8.
7. Install tool Nos. 11-2-441/445 to the camshaft on cylinder bank 1-4.
8. Using a suitable open-end wrench, align all camshafts in such a way that the tools fit on the cylinder heads without any gaps.
9. Fit tool Nos. 11-2-443 to tool Nos. 11-2-441/442/445/446 and secure them with tool No. 11-2-444 using the spark plug threads.
10. Install:
    
    
    Secondary sprockets together with chain to the camshafts on cylinder bank 5-8

    Fasteners on the exhaust camshaft sprocket and tighten
    
    
11. Remove the tool used to lock the chain tensioner in position.
12. Rotate the engine from 45 degrees BTDC in direction of rotation as far as TDC. Install tool No. 11-2-300 at the flywheel to lock the crankshaft in TDC position.
13. Assemble the primary sprocket and chain to the intake camshaft with the arrow pointing upwards (in cylinder axis) and the long bores centrally aligned. Install the fasteners snuggly.
14. Install tool No. 11-3-390 in the right timing case cover and with a suitable torque wrench, tension the tool to 11 inch lbs. (1.2 Nm).
15. Tighten the sprockets to 11 ft. lbs. (15 Nm) in the following order:
    
    
    All fasteners on the left exhaust camshaft

    The 3 fasteners in the right exhaust camshaft

    All fasteners on the left intake camshaft

    The 3 fasteners in the right intake camshaft
    
    
16. Remove:
    
    
    Tool Nos. 11-2-444/443/441/445 or their equivalents

    Tool Nos. 11-2-444/443/442/446 or their equivalents

    Tool No. 11-2-300 or the equivalent used to locked the crankshaft in TDC position
    
    
17. Turn the engine over once.
18. Tighten the remaining 3 fasteners on right exhaust camshaft and remaining 3 fasteners on the right intake camshaft to 11 ft. lbs. (15 Nm).
19. Relieve the load and remove tool No. 11-3-390 from the right timing case cover.
20. The balance of installation is the reverse of the removal procedure.
21. Check and top off all fluid levels as necessary.

Right Camshaft (Cylinder Bank 1-4)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Left and right cylinder head covers

   Spark plugs

   Fan assembly

   Top right timing case cover

   Splash guard

   Oil lines to the left and right cylinder head
   
   
3. Rotate the crankshaft in direction of rotation until the first cylinder is in TDC firing position.
4. Brace the camshaft on the hex head with a suitable open-end wrench and loosen the 3 accessible fasteners on each left sprocket approximately ¹ / ₂ a turn.
5. Turn the engine over once and loosen the remaining 3 fasteners on each left sprocket approximately ¹ / ₂ a turn.
6. Remove the primary sprocket from the right-hand intake camshaft (cylinder bank 1-4). Secure the chain to prevent it from dropping.
7. Rotate the engine to 45 degrees BTDC setting position. Rotate the crankshaft against direction of rotation until the gap in the increment gear fits in the tool No. 11-3-440.
8. Remove the fasteners on the exhaust camshaft sprocket. Do not remove the sprocket.
9. Compress the chain tensioner and install tool No. 11-3-420 to lock the tensioner in place.
10. Lift off both secondary camshaft sprockets together with the chain.
11. Rotate the intake and exhaust camshafts to the installed position.
12. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees upwards from the plane of the cylinder head.
13. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.
14. Loosen the both camshaft bearing caps uniformly from outside to inside¹ / ₂ turn.
15. Remove or disconnect the following:
    
    
    Bearing journal caps. Label each bearing cap to facilitate reassembly and position aside.

    Camshafts noting their locations

    Hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring.
    
    

To install:

1. If the tappets were removed, lubricate and install them with tool No. 11-32-250.
2. Lubricate and install the camshafts in their correct position.
   
   NOTE

   The intake camshaft will have a hexagon between cylinders 3 and 4. The exhaust camshaft will have the hexagon between cylinders 1 and 2.
   
   
3. Rotate the intake and exhaust camshafts to the installed position and perform the following:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees upwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
4. Install the bearing caps. Tighten the bearing caps from outside to inside in ¹ / ₂ turn increments. Tighten the bolts to 10-13 ft. lbs. (13-17 Nm).
   
   NOTE

   Do not confuse camshaft bearing caps of cylinders No. 1-4 and 5-8. The exhaust camshaft bearing caps are marked A1 through A5 counting from intake side. The intake camshaft bearing caps are marked E1 through E5 counting from the intake end.
   
   
5. Fit tool No. 11-3-430 to the camshaft. Rotate the camshaft until the marker bores face upwards, then proceed as follows:
   1. Install tool Nos. 11-2-442/446 to the camshaft on cylinder bank 5-8.
   2. Install tool Nos. 11-2-441/445 to the camshaft on cylinder bank 1-4.
   3. Using a suitable open-end wrench, align all camshafts in such a way that the tools fit on the cylinder heads without any gaps.
   4. Fit tool Nos. 11-2-443 to tool Nos. 11-2-441/442/445/446 and secure them with tool No. 11-2-444 using the spark plug threads.

   
   
6. Install:
   
   
   Secondary sprockets together with chain to the camshafts on cylinder bank 1-4

   Fasteners on the exhaust camshaft sprocket and tighten
   
   
7. Remove the tool used to lock the chain tensioner in position.
8. Rotate the engine from 45 degrees BTDC in direction of rotation as far as TDC setting. Install tool No. 11-2-300 ore equivalent at the flywheel to lock the crankshaft in TDC position.
9. Assemble the primary sprocket and chain with sensor pin to the intake camshaft with the arrow pointing upwards (in cylinder axis) and the long bores centrally aligned. Install the fasteners.
10. Install tool No. 11-2-400 to the right cylinder head (cylinder bank 1-4). Install tool No. 11-3-390 to tool No. 11-2-400. Using a suitable torque wrench, tension the tool to 11.5 inch lbs. (1.3 Nm).
11. Tighten the sprockets to 11 ft. lbs. (15 Nm) in the following order:
    
    
    3 fasteners on the left exhaust camshaft

    All fasteners on the right exhaust camshaft

    The 3 fasteners on the left intake camshaft

    All fasteners in the right intake camshaft
    
    
12. Remove:
    
    
    Tool Nos. 11-2-444/443/441/445 or the equivalent

    Tool Nos. 11-2-444/443/442/446 or the equivalent

    Tool No. 11-2-300 used to locked the crankshaft in TDC position
    
    
13. Turn the engine over once.
14. Tighten the remaining 3 fasteners on left exhaust camshaft and remaining 3 fasteners on left intake camshaft to 11 ft. lbs. (15 Nm).
15. Relieve the load and remove the tool Nos. 11-3-390 and 11-2-400 or their equivalents.
16. Install the remaining components in the reverse order of removal.
17. Check and top off the fluid levels as necessary.

M62 Engines

Fig. Gap in increment gear must fit in tool No. 11-3-440-M62 engines

Fig. Left side camshaft identification (cylinder bank 5 to 8): hex head (3) on intake camshaft between cylinders 7 and 8, hex head (4) on exhaust camshaft between cylinders 5 and 6-M62 engines

Fig. Right side camshaft identification (cylinder bank 1 to 4): hex-head (2) on intake camshaft between cylinders 3 and 4, hex-head (1) on exhaust camshaft between cylinders 1 and 2-M62 engines

Fig. Camshaft positioning-M62 engines

Fig. Install left-hand camshafts: Recesses in camshaft point downwards approximately 30-40 degrees from plane of cylinder head-M62 engines

Fig. Install right-hand camshafts: Recesses in camshaft point upward approximately 30-40 degrees from plane of cylinder head-M62 engines

Fig. Gap in increment gear must fit in tool No. 11-3-440-M62 engines

Fig. Left side camshaft identification (cylinder bank 5 to 8): hex head (3) on intake camshaft between cylinders 7 and 8, hex head (4) on exhaust camshaft between cylinders 5 and 6-M62 engines

Fig. Right side camshaft identification (cylinder bank 1 to 4): hex-head (2) on intake camshaft between cylinders 3 and 4, hex-head (1) on exhaust camshaft between cylinders 1 and 2-M62 engines

Fig. Camshaft positioning-M62 engines

Fig. Install left-hand camshafts: Recesses in camshaft point downwards approximately 30-40 degrees from plane of cylinder head-M62 engines

Fig. Install right-hand camshafts: Recesses in camshaft point upward approximately 30-40 degrees from plane of cylinder head-M62 engines

Left Camshaft (Cylinder Bank 5-8)

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Left and right cylinder head covers

   Spark plugs

   Top left timing case cover

   Splash guard

   Oil lines to the left and right cylinder head
   
   
3. Rotate the crankshaft in direction of rotation until cylinder number 1 is in Top Dead Center (TDC) firing position.
4. Brace the camshaft on the hex head with a suitable open-end wrench and loosen the 3 accessible fasteners on the right sprocket approximately¹₂
   1. Turn the engine over once and loosen the remaining 3 fasteners on each right sprocket approximately¹₂
   2. Remove the primary sprocket from the left-hand intake camshaft (cylinder bank 5-8). Secure the chain to prevent it from dropping into the engine.

   
   
5. Rotate the engine to 45 degrees Before Top Dead Center (BTDC). Rotate the crankshaft against direction of rotation until the gap in the increment gear fits in tool No. 11-3-440.
6. Remove or disconnect the following:
   
   
   Fasteners on the exhaust camshaft

   Fasteners on the exhaust camshaft sprocket. Do not remove the sprocket.
   
   
7. Compress the chain tensioner and install tool No. 11-3-420 to lock the tensioner in place.
8. Lift off both secondary camshaft sprockets together with the chain.
9. Rotate the intake and exhaust camshafts to the installed position as follows:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees downwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
10. Loosen the both camshaft bearing caps uniformly from outside to inside¹₂
11. Remove or disconnect the following:
    
    
    All bearing caps. Label each bearing cap to facilitate reassembly and place aside.

    Camshafts noting their locations

    Hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring.
    
    

To install:

1. If the lifters were removed, install them with tool No. 11-32-250.
2. Lubricate and install the camshafts in their correct position.

NOTE

The intake camshaft will have a hexagon between cylinders 7 and 8. The exhaust camshaft will have the hexagon between cylinders 5 and 6.

1. Rotate the intake and exhaust camshafts to the installed position as follows:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees downwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
2. Install the bearing caps, tightened from outside to inside in 1/2 turn increments to 9-13 ft. lbs. (12-17 Nm).

NOTE

Do not confuse camshaft bearing caps of cylinders No. 1-4 and 5-8. The exhaust camshaft bearing caps are marked A1 through A5. The intake camshaft bearing caps are marked E1 through E5 from intake end.

1. Fit tool No. 11-3-430 to the camshaft. Rotate the camshaft until the marker bores face upwards.
2. Install tool Nos. 11-2-442/446 to the camshaft on cylinder bank 5-8.
3. Install tool Nos. 11-2-441/445 to the camshaft on cylinder bank 1-4.
4. Using a suitable open-end wrench, align all camshafts in such a way that the tools fit on the cylinder heads without any gaps.
5. Fit tool Nos. 11-2-443 to tool Nos. 11-2-441/442/445/446 and secure them with tool No. 11-2-444 using the spark plug threads.
6. Install:
   
   
   Secondary sprockets together with chain to the camshafts on cylinder bank 5-8

   Fasteners on the exhaust camshaft sprocket and tighten
   
   
7. Remove the tool used to lock the chain tensioner in position.
8. Rotate the engine from 45 degrees BTDC in direction of rotation as far as TDC. Install tool No. 11-2-300 at the flywheel to lock the crankshaft in TDC position.
9. Assemble the primary sprocket and chain to the intake camshaft with the arrow pointing upwards (in cylinder axis) and the long bores centrally aligned. Install the fasteners snuggly.
10. Install tool No. 11-3-390 in the right timing case cover and with a suitable torque wrench, tension the tool to 11 inch lbs. (1.2 Nm).
11. Tighten the sprockets to 11 ft. lbs. (15 Nm) in the following order:
    
    
    All fasteners on the left exhaust camshaft

    The 3 fasteners in the right exhaust camshaft

    All fasteners on the left intake camshaft

    The 3 fasteners in the right intake camshaft
    
    
12. Remove:
    
    
    Tool Nos. 11-2-444/443/441/445 or their equivalents

    Tool Nos. 11-2-444/443/442/446 or their equivalents

    Tool No. 11-2-300 or the equivalent used to locked the crankshaft in TDC position
    
    
13. Turn the engine over once.
14. Tighten the remaining 3 fasteners on right exhaust camshaft and remaining 3 fasteners on the right intake camshaft to 11 ft. lbs. (15 Nm).
15. Relieve the load and remove tool No. 11-3-390 from the right timing case cover.
16. The balance of installation is the reverse of the removal procedure.
17. Check and top off all fluid levels as necessary.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Left and right cylinder head covers

   Spark plugs

   Top left timing case cover

   Splash guard

   Oil lines to the left and right cylinder head
   
   
3. Rotate the crankshaft in direction of rotation until cylinder number 1 is in Top Dead Center (TDC) firing position.
4. Brace the camshaft on the hex head with a suitable open-end wrench and loosen the 3 accessible fasteners on the right sprocket approximately ¹ / ₂ a turn.
   1. Turn the engine over once and loosen the remaining 3 fasteners on each right sprocket approximately ¹ / ₂ a turn.
   2. Remove the primary sprocket from the left-hand intake camshaft (cylinder bank 5-8). Secure the chain to prevent it from dropping into the engine.

   
   
5. Rotate the engine to 45 degrees Before Top Dead Center (BTDC). Rotate the crankshaft against direction of rotation until the gap in the increment gear fits in tool No. 11-3-440.
6. Remove or disconnect the following:
   
   
   Fasteners on the exhaust camshaft

   Fasteners on the exhaust camshaft sprocket. Do not remove the sprocket.
   
   
7. Compress the chain tensioner and install tool No. 11-3-420 to lock the tensioner in place.
8. Lift off both secondary camshaft sprockets together with the chain.
9. Rotate the intake and exhaust camshafts to the installed position as follows:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees downwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
10. Loosen the both camshaft bearing caps uniformly from outside to inside¹ / ₂ turn.
11. Remove or disconnect the following:
    
    
    All bearing caps. Label each bearing cap to facilitate reassembly and place aside.

    Camshafts noting their locations

    Hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring.
    
    

To install:

1. If the lifters were removed, install them with tool No. 11-32-250.
2. Lubricate and install the camshafts in their correct position.
   
   NOTE

   The intake camshaft will have a hexagon between cylinders 7 and 8. The exhaust camshaft will have the hexagon between cylinders 5 and 6.
   
   
3. Rotate the intake and exhaust camshafts to the installed position as follows:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees downwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
4. Install the bearing caps, tightened from outside to inside in 1/2 turn increments to 9-13 ft. lbs. (12-17 Nm).
   
   NOTE

   Do not confuse camshaft bearing caps of cylinders No. 1-4 and 5-8. The exhaust camshaft bearing caps are marked A1 through A5. The intake camshaft bearing caps are marked E1 through E5 from intake end.
   
   
5. Fit tool No. 11-3-430 to the camshaft. Rotate the camshaft until the marker bores face upwards.
6. Install tool Nos. 11-2-442/446 to the camshaft on cylinder bank 5-8.
7. Install tool Nos. 11-2-441/445 to the camshaft on cylinder bank 1-4.
8. Using a suitable open-end wrench, align all camshafts in such a way that the tools fit on the cylinder heads without any gaps.
9. Fit tool Nos. 11-2-443 to tool Nos. 11-2-441/442/445/446 and secure them with tool No. 11-2-444 using the spark plug threads.
10. Install:
    
    
    Secondary sprockets together with chain to the camshafts on cylinder bank 5-8

    Fasteners on the exhaust camshaft sprocket and tighten
    
    
11. Remove the tool used to lock the chain tensioner in position.
12. Rotate the engine from 45 degrees BTDC in direction of rotation as far as TDC. Install tool No. 11-2-300 at the flywheel to lock the crankshaft in TDC position.
13. Assemble the primary sprocket and chain to the intake camshaft with the arrow pointing upwards (in cylinder axis) and the long bores centrally aligned. Install the fasteners snuggly.
14. Install tool No. 11-3-390 in the right timing case cover and with a suitable torque wrench, tension the tool to 11 inch lbs. (1.2 Nm).
15. Tighten the sprockets to 11 ft. lbs. (15 Nm) in the following order:
    
    
    All fasteners on the left exhaust camshaft

    The 3 fasteners in the right exhaust camshaft

    All fasteners on the left intake camshaft

    The 3 fasteners in the right intake camshaft
    
    
16. Remove:
    
    
    Tool Nos. 11-2-444/443/441/445 or their equivalents

    Tool Nos. 11-2-444/443/442/446 or their equivalents

    Tool No. 11-2-300 or the equivalent used to locked the crankshaft in TDC position
    
    
17. Turn the engine over once.
18. Tighten the remaining 3 fasteners on right exhaust camshaft and remaining 3 fasteners on the right intake camshaft to 11 ft. lbs. (15 Nm).
19. Relieve the load and remove tool No. 11-3-390 from the right timing case cover.
20. The balance of installation is the reverse of the removal procedure.
21. Check and top off all fluid levels as necessary.

Right Camshaft (Cylinder Bank 1-4)

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Left and right cylinder head covers

   Spark plugs

   Fan assembly

   Top right timing case cover

   Splash guard

   Oil lines to the left and right cylinder head
   
   
3. Rotate the crankshaft in direction of rotation until the first cylinder is in Top Dead Center (TDC) firing position.
4. Brace the camshaft on the hex head with a suitable open-end wrench and loosen the 3 accessible fasteners on each left sprocket approximately¹₂
5. Turn the engine over once and loosen the remaining 3 fasteners on each left sprocket approximately¹₂
6. Remove the primary sprocket from the right-hand intake camshaft (cylinder bank 1-4). Secure the chain to prevent it from dropping.
7. Rotate the engine to 45 degrees Before Top Dead Center (BTDC) setting position. Rotate the crankshaft against direction of rotation until the gap in the increment gear fits in the tool No. 11-3-440.
8. Remove the fasteners on the exhaust camshaft sprocket. Do not remove the sprocket.
9. Compress the chain tensioner and install tool No. 11-3-420 to lock the tensioner in place.
10. Lift off both secondary camshaft sprockets together with the chain.
11. Rotate the intake and exhaust camshafts to the installed position.
12. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees upwards from the plane of the cylinder head.
13. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.
14. Loosen the both camshaft bearing caps uniformly from outside to inside¹₂
15. Remove or disconnect the following:
    
    
    Bearing journal caps. Label each bearing cap to facilitate reassembly and position aside.

    Camshafts noting their locations

    Hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring.
    
    

To install:

1. If the tappets were removed, lubricate and install them with tool No. 11-32-250.
2. Lubricate and install the camshafts in their correct position.

NOTE

The intake camshaft will have a hexagon between cylinders 3 and 4. The exhaust camshaft will have the hexagon between cylinders 1 and 2.

1. Rotate the intake and exhaust camshafts to the installed position and perform the following:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees upwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
2. Install the bearing caps. Tighten the bearing caps from outside to inside in¹₂

NOTE

Do not confuse camshaft bearing caps of cylinders No. 1-4 and 5-8. The exhaust camshaft bearing caps are marked A1 through A5 counting from intake side. The intake camshaft bearing caps are marked E1 through E5 counting from the intake end.

1. Fit tool No. 11-3-430 to the camshaft. Rotate the camshaft until the marker bores face upwards, then proceed as follows:
   1. Install tool Nos. 11-2-442/446 to the camshaft on cylinder bank 5-8.
   2. Install tool Nos. 11-2-441/445 to the camshaft on cylinder bank 1-4.
   3. Using a suitable open-end wrench, align all camshafts in such a way that the tools fit on the cylinder heads without any gaps.
   4. Fit tool Nos. 11-2-443 to tool Nos. 11-2-441/442/445/446 and secure them with tool No. 11-2-444 using the spark plug threads.

   
   
2. Install:
   
   
   Secondary sprockets together with chain to the camshafts on cylinder bank 1-4

   Fasteners on the exhaust camshaft sprocket and tighten
   
   
3. Remove the tool used to lock the chain tensioner in position.
4. Rotate the engine from 45 degrees BTDC in direction of rotation as far as TDC setting. Install tool No. 11-2-300 ore equivalent at the flywheel to lock the crankshaft in TDC position.
5. Assemble the primary sprocket and chain with sensor pin to the intake camshaft with the arrow pointing upwards (in cylinder axis) and the long bores centrally aligned. Install the fasteners.
6. Install tool No. 11-2-400 to the right cylinder head (cylinder bank 1-4). Install tool No. 11-3-390 to tool No. 11-2-400. Using a suitable torque wrench, tension the tool to 11.5 inch lbs. (1.3 Nm).
7. Tighten the sprockets to 11 ft. lbs. (15 Nm) in the following order:
   
   
   3 fasteners on the left exhaust camshaft

   All fasteners on the right exhaust camshaft

   The 3 fasteners on the left intake camshaft

   All fasteners in the right intake camshaft
   
   
8. Remove:
   
   
   Tool Nos. 11-2-444/443/441/445 or the equivalent

   Tool Nos. 11-2-444/443/442/446 or the equivalent

   Tool No. 11-2-300 used to locked the crankshaft in TDC position
   
   
9. Turn the engine over once.
10. Tighten the remaining 3 fasteners on left exhaust camshaft and remaining 3 fasteners on left intake camshaft to 11 ft. lbs. (15 Nm).
11. Relieve the load and remove the tool Nos. 11-3-390 and 11-2-400 or their equivalents.
12. Install the remaining components in the reverse order of removal.
13. Check and top off the fluid levels as necessary.

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Left and right cylinder head covers

   Spark plugs

   Fan assembly

   Top right timing case cover

   Splash guard

   Oil lines to the left and right cylinder head
   
   
3. Rotate the crankshaft in direction of rotation until the first cylinder is in Top Dead Center (TDC) firing position.
4. Brace the camshaft on the hex head with a suitable open-end wrench and loosen the 3 accessible fasteners on each left sprocket approximately ¹ / ₂ a turn.
5. Turn the engine over once and loosen the remaining 3 fasteners on each left sprocket approximately ¹ / ₂ a turn.
6. Remove the primary sprocket from the right-hand intake camshaft (cylinder bank 1-4). Secure the chain to prevent it from dropping.
7. Rotate the engine to 45 degrees Before Top Dead Center (BTDC) setting position. Rotate the crankshaft against direction of rotation until the gap in the increment gear fits in the tool No. 11-3-440.
8. Remove the fasteners on the exhaust camshaft sprocket. Do not remove the sprocket.
9. Compress the chain tensioner and install tool No. 11-3-420 to lock the tensioner in place.
10. Lift off both secondary camshaft sprockets together with the chain.
11. Rotate the intake and exhaust camshafts to the installed position.
12. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees upwards from the plane of the cylinder head.
13. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.
14. Loosen the both camshaft bearing caps uniformly from outside to inside¹ / ₂ turn.
15. Remove or disconnect the following:
    
    
    Bearing journal caps. Label each bearing cap to facilitate reassembly and position aside.

    Camshafts noting their locations

    Hydraulic valve lifters. To remove, use tool No. 11-3-250 to pull them out of the cylinder head. Be sure that no damage occurs to the guides in the head. Inspect the bearing surfaces of the tappets for wear and scoring.
    
    

To install:

1. If the tappets were removed, lubricate and install them with tool No. 11-32-250.
2. Lubricate and install the camshafts in their correct position.
   
   NOTE

   The intake camshaft will have a hexagon between cylinders 3 and 4. The exhaust camshaft will have the hexagon between cylinders 1 and 2.
   
   
3. Rotate the intake and exhaust camshafts to the installed position and perform the following:
   1. Using tool No. 11-3-430, rotate the camshafts until the recess in both camshaft flange points approximately 30-40 degrees upwards from the plane of the cylinder head.
   2. Check the installed position by installing tool No. 11-2-430 to the camshafts. The cylinder designation of the tool must point upwards.

   
   
4. Install the bearing caps. Tighten the bearing caps from outside to inside in ¹ / ₂ turn increments. Tighten the bolts to 10-13 ft. lbs. (13-17 Nm).
   
   NOTE

   Do not confuse camshaft bearing caps of cylinders No. 1-4 and 5-8. The exhaust camshaft bearing caps are marked A1 through A5 counting from intake side. The intake camshaft bearing caps are marked E1 through E5 counting from the intake end.
   
   
5. Fit tool No. 11-3-430 to the camshaft. Rotate the camshaft until the marker bores face upwards, then proceed as follows:
   1. Install tool Nos. 11-2-442/446 to the camshaft on cylinder bank 5-8.
   2. Install tool Nos. 11-2-441/445 to the camshaft on cylinder bank 1-4.
   3. Using a suitable open-end wrench, align all camshafts in such a way that the tools fit on the cylinder heads without any gaps.
   4. Fit tool Nos. 11-2-443 to tool Nos. 11-2-441/442/445/446 and secure them with tool No. 11-2-444 using the spark plug threads.

   
   
6. Install:
   
   
   Secondary sprockets together with chain to the camshafts on cylinder bank 1-4

   Fasteners on the exhaust camshaft sprocket and tighten
   
   
7. Remove the tool used to lock the chain tensioner in position.
8. Rotate the engine from 45 degrees BTDC in direction of rotation as far as TDC setting. Install tool No. 11-2-300 ore equivalent at the flywheel to lock the crankshaft in TDC position.
9. Assemble the primary sprocket and chain with sensor pin to the intake camshaft with the arrow pointing upwards (in cylinder axis) and the long bores centrally aligned. Install the fasteners.
10. Install tool No. 11-2-400 to the right cylinder head (cylinder bank 1-4). Install tool No. 11-3-390 to tool No. 11-2-400. Using a suitable torque wrench, tension the tool to 11.5 inch lbs. (1.3 Nm).
11. Tighten the sprockets to 11 ft. lbs. (15 Nm) in the following order:
    
    
    3 fasteners on the left exhaust camshaft

    All fasteners on the right exhaust camshaft

    The 3 fasteners on the left intake camshaft

    All fasteners in the right intake camshaft
    
    
12. Remove:
    
    
    Tool Nos. 11-2-444/443/441/445 or the equivalent

    Tool Nos. 11-2-444/443/442/446 or the equivalent

    Tool No. 11-2-300 used to locked the crankshaft in TDC position
    
    
13. Turn the engine over once.
14. Tighten the remaining 3 fasteners on left exhaust camshaft and remaining 3 fasteners on left intake camshaft to 11 ft. lbs. (15 Nm).
15. Relieve the load and remove the tool Nos. 11-3-390 and 11-2-400 or their equivalents.
16. Install the remaining components in the reverse order of removal.
17. Check and top off the fluid levels as necessary.

M73 5.4L Engines

Fig. At TDC, the dowel pins in the camshaft sprockets should face each other-M73 5.4L engines

Fig. Camshaft alignment gauge-M73 5.4L engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Coolant

   Fan assembly

   Both intake manifolds and distributor housings

   Cylinder head covers

   Mounting bolts and lift out the upper timing cover
   
   
3. Set the engine to TDC. Install a holder in the crankshaft. The valves of cylinders 1 and 7 should be closed and the dowel pins in the camshafts should face in.
4. Press off the anti-tamper lock for the chain tensioner with a screwdriver. Loosen the nut, then loosen the adjusting screw several turns, and then remove the plug. Remove the timing chain tensioning piston, using care not to lose the spring that is between the plug and the piston.
5. Remove or disconnect the following:
   
   WARNING

   The bearing caps are matched with the bearings, do not mix the order of the caps.
   
   
   
   
   Mounting bolts for the timing chain guide, and remove the guide, then remove the tensioning rail

   Mounting bolts on the camshaft sprockets, and carefully remove the sprockets. Do not allow the timing chain to fall into the engine.

   Oil pipe mounting bolts from the top of the camshaft bearings

   Camshaft
   
   

To install:

1. With the crankshaft positioned at TDC, install the camshaft with the dowel pin facing the center of the engine. Position the bearing caps and install the mounting bolts from inside to outside. Tighten the bolts to 11 ft. lbs. (15 Nm).
2. Hold both camshafts in position with tool No. 11-3-190.
3. Mount the oil pipes with the oil outlet bores facing the camshaft. Install the hollow union bolt in the bearing cover. Install the mounting bolts and tighten to 108 inch lbs. (12 Nm).
4. Install or connect the following:
   
   
   Camshaft sprocket mounting bolts finger-tight. Position the timing chain on the sprockets in the opposite direction of engine rotation, beginning at the crankshaft. Verify that the timing chain is correctly aligned on all the sprockets, and remove the crankshaft holder.

   Timing chain guide and tensioning rail

   Timing chain tensioner

   Camshaft sprocket bolts: 89 inch lbs. (10 Nm)

   Upper timing cover and a new gasket

   Cylinder head covers

   Both intake manifolds and distributor housings

   Fan assembly

   Coolant and all remaining fluids

   Negative battery cable
   
   

S14 Engine

NOTE

To perform this operation it is necessary to have Tool No. 11 3 010 or equivalent. This is necessary to permit safe removal of the camshaft bearing caps and then safe release of the tension the valve springs put on the camshafts. The job also requires an adapter to keep the camshaft sprockets from turning while loosening and tightening their mounting bolts.

1. Disconnect the negative battery cable. Remove the cylinder head cover. Remove the fan cowl and the fan.
2. Remove the mounting bolts and remove the distributor cap. Remove the mounting screws and remove the rotor. Unscrew the distributor adapter and the protective cover underneath. Inspect the O-ring that runs around the protective cover and replace it, if necessary.
3. Remove the 2 bolts and remove the protective cover from in front of the right side (intake) camshaft. Remove the bolts and remove the distributor housing from in front of the left (exhaust) side cam. Inspect the O-rings, and replace them, if necessary.
4. Remove the 6 mounting bolts from the cover at the rear end of the cylinder head and remove it. Replace the gasket. Note that on the S14 engine, 2 of these bolts are longer. These fit into the 2 holes that are sleeved.
5. Remove the 2 socket head bolts, located at the front of the head, which mount the upper timing chain guide rail. Then, remove the upper guide rail.
6. Turn the crankshaft to set the engine at No. 1 cylinder Top Dead Center (TDC). On the S14 engine, valves for No. 4 will be at overlap position-both valves just slightly open with timing marks at TDC.

NOTE

The next item to be removed is a plug which keeps the tensioner piston inside its hydraulic cylinder against considerable spring pressure. Use a socket wrench and keep pressure against the outer end of the plug, pushing inward, so spring pressure can be released very gradually once the plug's threads are free of the block.

1. Remove the plug from the tensioner piston, and then release spring tension. Remove the spring and then the piston. Check the length of the spring. It must be 6.240-6.280 inches (158.5-159.5mm) in length; otherwise, replace it to maintain stable timing chain tension.

NOTE

The timing chain should remain engaged on the crankshaft sprocket while removing the camshafts. Otherwise, it will be necessary to do additional work to restore proper timing. Keep the timing chain under slight tension by supporting it at the top while removing the camshaft sprockets.

1. Pry open the lock plates for the camshaft sprocket mounting bolts. Install an adapter to hold the sprockets still and remove the mounting bolts.
2. Using an adapter to keep the sprockets from turning and putting tension on the timing chain, loosen and remove the sprocket mounting bolts, keeping the chain supported.
3. Mount the special tool on the timing case, which mounts to the top of the head. Then, tighten the tool's shaft to the stop. This will hold both camshafts down against their lower bearings. Also, mark the camshafts as to exhaust and intake.
4. Remove the mounting bolts. Mark the camshaft bearing caps. It is possible to save time by keeping the caps in order, although they are marked for installation in the same positions.
5. Once all bolts are removed, slowly crank backwards on the tool's shaft to gradually release the tension on the camshaft bearing caps. Once all tension is released, remove the tool.
6. Carefully, remove the camshafts in such a way as to avoid nicking any bearing surfaces or cams.

To install:

1. Oil all bearing and camshaft surfaces with clean engine oil. Carefully, install the camshafts, marked E for intake and A for exhaust, to avoid nicking any wear surfaces. The camshafts should be turned so the groove between the front camshaft and sprocket mounting flange faces straight up. Install the special tool and tighten down on the shaft to seat the camshaft bearings.
2. Install all bearing caps in order or as marked. Torque the attaching bolts to 15-17 ft. lbs. (20-23 Nm). Then, release the tension provided by the tool by turning the bolt and remove the tool.
3. Install the intake sprocket (marked E), install the lock plate, and install the mounting bolts. Use the adapter to keep the sprocket from turning, and torque the bolts to 80 inch lbs. (9 Nm). Do the same for the exhaust side sprocket. Make sure the timing chain stays in time.
4. Slide the timing chain tensioner piston into the opening in the cylinder in the block. Install the spring with the conically wound end facing the plug. Install the plug into the end of the sprocket and then install it over the spring. Use the socket wrench to depress the spring until the plug's threads engage with those in the block. Start the threads in carefully and then torque the plug to 27-31 ft. lbs. (37-42 Nm).
5. Crank the engine forward just 1 turn in normal direction of rotation. Now, 1 camshaft groove on each side should face toward the center of the head and 1 on each side should face the case boss on the front bearing cap. Lock the sprocket mounting bolts with the tabs on the lockplates.
6. Reverse the remaining removal procedures to complete the installation. Before final tightening of the mounting nuts for the guide rail for the top of the timing chain, go back and forth, measuring the clearance between the sprockets and the center of the guide rail to center it. Then, tighten the mounting nuts.

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