Where are timing chain tensioners? I need to change them.Does left one have an electrical connection? Thanks

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, this engine user copper links on the chain align the copper links with the marks shown on the diagram below. Please let me know if you have more questions, and thanks for using FixYa.

To install:

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

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

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

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

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

    Fig. Front cover bolt tightening sequence-4.6L engine
    
    
    
    

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

20. Lubricate the engine front cover and oil seal lip with clean engine oil and install the seal using a seal installer.
21. Apply sealant to the Woodruff key slot in the crankshaft pulley, then press on the crankshaft damper.
22. Tighten the crankshaft damper as follows:
    1. Step 1: 66 ft. lbs. (90 Nm).
    2. Step 2: Loosen the bolt one full turn.
    3. Step 3: 37 ft. lbs. (50 Nm).
    4. Step 4: 90 degrees.
    
    
23. Connect the crankshaft position sensor connector.
24. Install the power steering pump and tighten the bolts to 18 ft. lbs. (25 Nm).
25. Install the wiring harness retainer to the power steering stud bolt.
26. Install the power steering pump pulley shield.
27. Install the water pump pulley.
28. Install the J bracket to the engine front cover stud bolt.
29. Install both left and right camshaft position sensor connectors.
30. Install both left and right radio interference capacitors.
31. Connect the hoses from the coolant crossover.
32. Install the valve covers. See the procedure under Cylinder Head.
33. Install the right side idler pulley.
34. Install the accessory drive belt.
35. Install the coolant degas bottle.
36. Connect the negative battery cable.
37. Fill the crankcase with clean engine oil.
38. Start the engine. Check for leaks and proper operation.

timing chains let you know when its time to change them as they rattle but if you do a rebuild at say 200k then obviously change the chain/tensioner

Hi, this engine uses plated links in the chain to match marks on the gears. See figure and installation procedure below. Let me know if you have any questions and thanks for using FixYa.

1. Install the timing chain by performing the following procedure:

1. Verify that the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing.
2. Place the left side primary timing chain sprocket onto the chain, while aligning the timing mark on the sprocket to the 2 plated links on the chain.
3. Lower the chain with the left sprocket through the left cylinder head opening.
4. Loosely position the left camshaft sprocket over the camshaft hub.
5. Align the plated link to the crankshaft sprocket timing mark.
6. Position the timing chain around the water pump drive sprocket.
7. Align the right camshaft sprocket timing mark to the plated link on the timing chain and loosely position the sprocket over the camshaft hub.
8. Verify that all the plated links are aligned to their proper timing marks.
   

1. Install the left lower timing chain guide and tensioner. Torque the bolts to 21 ft. lbs. (28 Nm).
   NOTE Inspect the timing chain guide access plug O-rings before installing. Replace damaged O-rings as necessary.
   
2. Install the timing chain guide access plug to the left cylinder head and torque to 15 ft. lbs. (20 Nm).
   NOTE To reset the timing chain tensioner, oil will first need to be purged from the tensioner.

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

1. Remove the tensioner from the tensioner housing.
2. Place the check ball end of the tensioner into the shallow end of the Tensioner Resetting Special tool 8186.
3. Using hand pressure, slowly depress the tensioner until oil is purged from the cylinder.
4. Reinstall the tensioner into the tensioner housing.

1. Reset the timing chain tensioner using the following procedure:

1. Position the cylinder plunger into the deeper side of the Tensioner Resetting special tool 8186. Apply a downward force until the tensioner is reset.
   

WARNING

Ensure that the tensioner is properly reset. The tensioner body must be bottomed against the top edge of the Tensioner Resetting Special tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.

1. Install the chain tensioner into the right cylinder head.
   
2. At the right cylinder head, insert a 3 / 8 in. square drive extension with a breaker bar into the intake camshaft drive hub. Rotate the camshaft until the camshaft hub aligns with the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and torque to 21 ft. lbs. (28 Nm).
3. Turn the left camshaft by inserting a 3 / 8 in. square drive extension with a breaker bar into the intake camshaft drive hub. Rotate the camshaft until the camshaft hub aligns with the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and torque to 21 ft. lbs. (28 Nm).
4. If necessary, rotate the engine slightly clockwise to remove any slack in the timing chain.
5. To arm the timing chain tensioner: Use a flat-bladed prytool to gently pry the tensioner arm towards the tensioner slightly. Then, release the tensioner arm. Verify the tensioner extends.
6. Inspect and replace the timing chain cover gasket and oil seal.
7. Apply a 1 / 8 in. (3mm) bead of sealer at the parting line of the oil pan and engine block.
   NOTE When installing the timing cover, guide the seal over the crankshaft to prevent damage to the seal-s lip.
   

Install or connect the following:

Timing cover and gasket and torque the M10 bolts to 40 ft. lbs. (54 Nm) and the M6 bolts to 105 inch lbs. (12 Nm)

Accessory drive belt tensioner pulley

Power steering pump

Crankshaft damper

Crankshaft center bolt and torque the bolt to 125 ft. lbs. (170 Nm) using tool 8191

Accessory drive belts

Fan module and electrical wiring harness

Upper radiator crossmember

Negative battery cable

To Install:

1. Install balance shaft drive gear onto the left camshaft.
2. Install the camshaft sprockets and new bolts finger tight.
3. Using a vise, compress the timing chain tensioner plunger.

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

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

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

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

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

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

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

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

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

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

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

if this is in fact the problem then yes you need to change this as soon as possible. The chain tensioner tensions the timing chain inside your engine. If there is too much slack in the chain, it can slip a couple teeth in its gears or possibly even fall off or break! If this occurs it will be time for a new engine. It will be pretty expensive, around 1000 bucks or more. But it could cost 2 or 3 times as much if left alone. My best advise would be to find a friend or family member who can do this for cheaper. It is a pretty intense job so the average person may not want to try this. I hope this helps! Vote yes if so. Thanks!

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

FORD: 1997-2000 EXPLORER, MOUNTAINEER
ISSUE: A "knocking" noise at start up for up to 2 minutes from the left hand front chain cassette area may occur on some vehicles. After engine shutdown, the tensioner oil supply gallery empties. The noise may be due to air entering the left hand tensioner when the engine is restarted.
ACTION: Replace the left hand camshaft tensioner with a revised Tensioner Kit. Refer to the Instruction Sheet within the Tensioner Kit for service procedure details.
WARNING: THE XU2Z-6K254-AA TENSIONER KIT IS FOR INSTALLATION ON THE LEFT SIDE OF THE ENGINE ONLY. INSTALLATION OF THIS KIT ON THE RIGHT SIDE OF THE ENGINE MAY RESULT IN ENGINE FAILURE. IF A TENSIONER IS NEEDED FOR THE RIGHT SIDE OF THE ENGINE, USE KIT XU3Z-6K254-BA.
PART NUMBER PART NAME XU2Z-6K254-AA Tensioner Kit - Left Side XU3Z-6K254-BA Tensioner Kit - Right Side

SECTION 303-01B: Engine — 4.0L SOHC 1998 Explorer/Mountaineer Workshop Manual
IN-VEHICLE REPAIR Timing Drive Components —LH Hydraulic Chain Tensioner Removal and Installation

1. Remove the upper intake manifold. For additional information, refer to Intake Manifold—Upper in this section.

Intake Manifold —Upper Removal

1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01 .

1. Remove the air cleaner outlet tube (9B659); refer to Section 303-12 .

1. Remove the bolts and the accelerator control splash shield.

1. Remove the accelerator cable (9A758) and speed control actuator cable (9A825).
   1. Pull up on speed control actuator cable to remove.
   1. Rotate the throttle body cam and remove the accelerator cable from the cam.

1. Remove the screws, the accelerator cable and speed control actuator cable.

1. Disconnect the RH upper intake manifold vacuum connection.

1. Disconnect the idle air control (IAC) valve electrical connector.

1. Disconnect the TP sensor electrical connector.

1. Disconnect the engine vacuum regulator (EVR) and the variable induction system (VIS) solenoid electrical connections.

1. Disconnect the crankcase ventilation hose (6853).

1. Disconnect the power brake booster vacuum line.

1. Remove the 12 bolts.

1. NOTE: Inspect the O-rings and replace as necessary.
   Disconnect the LH fuel vapor management valve (VMV) hose.

1. NOTE: Inspect the O-rings and replace as necessary.
   Disconnect the RH VMV hose and remove the upper intake manifold.

1. Remove the thermostat housing. For additional information, refer to Section 303-03 .

1. Remove the LH camshaft tensioner.
   • If using a new washer, tighten to 44 Nm (32 lb-ft).
   • If using the old washer, tighten to 67 Nm (49 lb-ft).

1. Remove the pipe plug, and the oil volume reduction plug.

1. NOTE: Be sure to install the new oil volume reduction plug supplied with the hydraulic chain tensioner.
   To install, reverse the removal procedure.

please rate as fixed if this helps you