Can't get the housing to align after replacing the chain

TIMING CHAIN, REPLACE Caution: With the timing chain removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact. 1. Disconnect and isolate battery ground cable. 2. Drain coolant into suitable container. 3. Remove accessory drive belt. 4. Remove front cover as follows: a. Remove coolant reservoir or surge tank. b. Attach engine support tool Nos. J-28467-360 and J-28467-400, or equivalents, onto alternator stud-ended bolt. c. Remove front cover upper mounting screws. d. Remove engine mount and bracket adapter. Discard adapter bolts. e. Raise and support vehicle with jack stands. f. Remove righthand front wheel and tire assembly, then the righthand splash shield. g. Hold balancer in position using harmonic balancer GM tool No. J-38122, or equivalent, remove mounting bolt and balancer using puller GM tool No. J-24420-C, or equivalent. h. Remove front cover lower mounting bolt. i. Lower vehicle. j. Remove front cover and gaskets. 5. Rotate crankshaft in clockwise direction until camshaft sprocket timing dowel pin holes line up with timing chain housing holes, Fig. 1. 6. Remove timing chain guides. 7. Raise and support vehicle with jack stands. 8. Ensure timing chain slack is above tensioner, then remove tensioner, Fig. 2. 9. Disconnect timing chain from tensioner shoe grooves and remove shoe using suitable screwdriver under timing chain while pulling shoe outward. 10. If removing tensioner shoe is difficult, proceed as follows: a. Lower vehicle. b. Hold intake camshaft sprocket in position with camshaft sprocket wrench GM tool No. J-39579, or equivalent. c. Remove sprocket bolt and washer. d. Remove washer and install bolt into camshaft by hand. e. Position suitable three-jaw puller into intake camshaft sprocket relief holes and remove sprocket. Do not pry on camshaft sprocket as damage to sprocket or timing chain housing may result. 11. Remove mounting bolts and tensioner. Caution: Tensioner is spring loaded. 12. Mark timing chain and crankshaft sprocket for installation. 13. Remove timing chain. 14. Apply adhesive sealant compound GM part No. 12345493, or equivalent, on camshaft sprocket bolt. 15. Hold camshaft sprocket in position with camshaft sprocket GM tool No. J-39579, or equivalent, then tighten mounting bolt and washer. 16. Position camshafts using camshaft sprocket timing alignment pin tools No. J-36800, or equivalent, through camshaft sprockets' into timing chain housing holes, Fig. 1. 17. If camshafts are out of position and must be rotated more than 1/8 turn, proceed as follows: a. Rotate crankshaft clockwise to 90° off TDC. b. Position camshafts and install dowels. c. Rotate crankshaft counterclockwise back to TDC. Caution: Rotating crankshaft clockwise to TDC will damage valves and pistons. 18. Place timing chain over exhaust camshaft sprocket, coolant pump or idler sprocket and crankshaft sprocket. 19. Remove intake camshaft timing pin and attach camshaft sprocket GM tool No. J-39579, or equivalent. 20. Rotate intake camshaft sprocket counterclockwise with tool until timing chain can be installed over sprocket. 21. Release tool. Timing chain tension between camshaft sprockets should tighten. 22. Timing pin should easily fit through intake camshaft sprocket timing hole into timing chain housing timing hole. If timing pin does not fit easily, repeat procedure. 23. With timing pins installed, raise and support vehicle with jack stands. 24. With timing chain slack between intake camshaft sprocket and crankshaft sprocket, timing marks on crankshaft and engine block should be aligned. If crankshaft timing marks are not aligned, move timing chain one tooth forward or rearward to remove slack, then align marks. 25. Load tensioner to zero position by forming keeper out of heavy gauge wire. 26. Apply slight force on tensioner blade to compress plunger. 27. Insert small screwdriver into reset access hole and pry ratchet pawl away from ratchet teeth while forcing plunger completely in hole. 28. Install keeper between access hole and blade. 29. Install tensioner to chain housing and inspect plunger installation again. Ensure long end is toward crankshaft. 30. Lower vehicle enough to remove alignment dowel pins. 31. Rotate crankshaft two revolutions clockwise. 32. Align crankshaft keyway with cylinder block alignment mark and insert timing pins through camshaft sprockets into timing chain housing timing holes. 33. Timing pins should slide easily through timing holes. If timing pins cannot be easily inserted, repeat procedure to properly time engine. 34. Install timing chain guides and front cover. Torque front cover bolts to 108 inch lbs. 35. Torque engine mount bracket adapter bolts to 81 ft. lbs., then tighten an additional 90° turn. 36. Install accessory drive belt. 37. Inspect cooling system and fill to proper level with recommended coolant, as required. 38. Fill engine crankcase to proper level with recommended engine oil. 39. Connect battery ground cable. 40. Start engine and confirm proper operation, and ensure there are no leaks. 41. Clear DTC(s) using a suitably programmed scan tool. 42. These engines do not require a specified bleed procedure. After filling cooling system, run engine to operating temperature with radiator/pressure cap off. Air will then be automatically bled through opening. Hope that helps.

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

Water Pump Replacement (2.4L)
Removal Procedure

1. Drain the coolant. Recover the coolant. Refer to Cooling System Draining and Filling.
2. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Exhaust.
3. Remove the coolant intake pipe. Refer to Engine Coolant Inlet Pipe Replacement in Engine Cooling.
4. Lower the vehicle.
5. Disconnect the heater hose quick connect from the heater outlet pipe.
6. Remove the timing chain and tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L. (see below procedure)
7. Remove the water pump cover-to-cylinder block bolts.
8. Remove water pump pipe to cylinder block bolt.
9. Remove the 3?water pump-to-timing chain housing nuts.
10. Remove the water pump and cover assembly.
11. Remove the water pump cover-to-coolant pump assembly bolts.
12. Clean all sealing surfaces.

Installation Procedure

Important: Before you install the coolant pump, read the entire procedure. Follow the tightening sequences in order to avoid part damage and to provide proper sealing.


1. Install the pump cover bolts. Hand tighten the bolts.
2. Install water pump cover assembly.
3. Install the cover-to-block bolts. Hand tighten the bolts.
4. Install the coolant pump-to-timing chain housing nuts. Hand tighten the nuts.
Notice: Refer to Fastener Notice in Cautions and Notices.

5. Torque in sequence as follows:
   1. Tighten the water pump-to-timing chain housing nuts.
      Tighten
      Tighten water pump to timing chain housing nuts to 26?Y (19?lb?ft).
   2. Tighten the pump cover-to-pump assembly bolts.
      Tighten
      Tighten the water pump cove to water pump bolts to 14?Y (124?lb?in).
   3. Tighten the coolant pump cover-to-engine block bolts. Tighten the bottom bolt first.
      Tighten
      Tighten water pump to engine block bolts to 26?Y (19?lb?ft).
6. Install heater hose to pipe on water pump.
7. Install the exhaust manifold and install new gaskets. Refer to Exhaust Manifold Replacement in Engine Exhaust.
8. Install oil level indicator tube and indicator. Refer to Oil Level Indicator Tube Replacement in Engine Mechanical-2.4L.
9. Connect the brake vacuum pipe to the cam housing.
10. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
11. Install catalytic converter to to manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
12. Install the coolant inlet pipe. Refer to Engine Coolant Inlet Pipe Replacement.
13. Install the timing chain and tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement in Engine Mechanical - 2.4L.
14. Lower the vehicle.
15. Connect the oxygen sensor connector.
16. Fill cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
17. Inspect the system for leaks.

Camshaft Timing Chain, Sprocket, and Tensioner Replacement
Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.
Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of reassembly.

1. Disconnect the negative battery cable.
2. Remove the engine front cover. Refer to Engine Front Cover Replacement.
3. Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes align with the holes in the timing chain housing.
4. Set the crankshaft sprocket keyway pointing upwards. Align with the centerline of the cylinder bores. This is the timed position.
5. Remove the timing chain guides.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Ensure that all of the slack in the timing chain is above the tensioner assembly.
8. Remove the timing chain tensioner bolts and the tensioner.
9. Remove the tensioner shoe. Use a small locking ring plier in order to engage the hole in the locking tab and remove the shoe from the stud.
Notice: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur.
Important: Mark the timing chain and the crankshaft sprocket prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur.

10. Mark the crankshaft sprocket and the timing chain outer surface.
11. Remove the timing chain.
12. Lower the vehicle.
13. Holding the intake camshaft sprocket with J 39579, remove the sprocket bolt and washer.
14. Remove the washer from the bolt and rethread the bolt back into the camshaft.
15. Using a 3-jaw puller and the relief holes in the sprocket, remove the intake camshaft sprocket.
16. Repeat this procedure for the exhaust camshaft sprocket.
17. Clean the old sealant from the bolt with a wire brush.
18. Clean the threaded hole in the camshaft with a round nylon bristle brush.
19. Inspect the parts for wear. Replace the parts as necessary.Some scoring of the timing chain shoe and the guides is normal.
20. Replace the timing chain shoe or guides if the scoring exceeds 1.12?mm (45?in).

Installation Procedure

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

Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur.
Important: The side of the timing chain that was marked during removal must be showing when the chain is installed.

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

Important: Use the following steps in order to reset the timing chain tensioner assembly to the zero position.

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


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


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


Important: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started.

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


19. Install the timing chain guides.
20. Install the engine front cover. Refer to Engine Front Cover Replacement.
21. Connect the negative battery cable.
    Tighten
    Tighten the bolt to 16?Y (12?lb?ft).

Did you take pictures while removing the originals? It's always a good habit. Below are the instructions you need to follow. Your own pics are very helpful when doing a big job like this.

1. Disconnect negative battery (1) cable.
2. Drain cooling system.
3. Remove upper intake manifold.
4. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.

CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

1. Align crankshaft sprocket timing mark to mark on oil pump housing (2). The mark on oil pump housing is 600 ATDC of #1 cylinder.

CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

1. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head.

1. Disconnect and remove camshaft position sensor (4) from left cylinder head.
2. Remove timing chain guide access plugs (3) from cylinder heads.

NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.

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

INSTALLATION

1. Inspect all sprockets (4,9,11) and chain guides (2,5,10). Replace if worn.
2. For crankshaft sprocket installation procedures Refer to CRANKSHAFT SPROCKET.
3. If removed, install right and left side short chain guides (11). Tighten attaching bolts to 28 Nm (250 inch lbs.) .
4. Align crankshaft sprocket timing mark to the mark on oil pump housing (3).

NOTE: Lubricate timing chain and guides with engine oil before installation.

1. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (1).

1. Lower the primary chain with left side sprocket through the left cylinder head opening.

NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.

1. Loosely position left side camshaft sprocket over camshaft hub.
2. Align timing (plated) link to the crankshaft sprocket timing mark (3).
3. Position primary chain onto water pump drive sprocket (10).
4. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely position over camshaft hub.
5. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
6. Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 28 Nm (250 inch lbs.) .

NOTE: Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

1. Install chain guide access plugs to cylinder heads. Tighten plugs to 20 Nm (15 ft. lbs.) .

NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

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

1. Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
2. Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

1. Reset timing chain tensioner using the following procedure:

1. Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
2. Apply a downward force until tensioner is reset.

NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball.

CAUTION: Ensure the tensioner is properly reset. The tensioner body (4) must bottom against the top edge of Special Tool 8186 (3). Failure to properly perform the resetting procedure may cause tensioner jamming.

NOTE: Inspect the tensioner O-ring (2) for nicks or cuts and make sure the snap ring (1) is correctly installed, replace as necessary.

1. Install the reset chain tensioner (1) into the right cylinder head.
2. Position tensioner retaining plate (2) and tighten bolts (1) to 12 Nm (105 inch lbs.) .

1. Starting at the right cylinder bank, first position the camshaft damper (1) (if equipped) on camshaft hub, then insert a 3/8 square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 inch lbs.) .
2. Turn the left side camshaft by inserting a 3/8 square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 inch lbs.).
3. Rotate engine slightly clockwise to remove timing chain slack, if necessary.

1. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then release the tensioner arm. Verify the tensioner is activated (extends).

1. Install camshaft position sensor (2) and connect electrical connector.
2. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
3. Install upper intake manifold.

NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds.

1. Fill cooling system.

please let me know if you have questions.
2.4L Engine
NOTE It is recommended that the entire procedure be reviewed before attempting to service the timing chain.

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the cooling system.
3. Remove or disconnect the following: Negative battery cable, Coolant surge tank, Accessory drive belt, Alternator
4. Install an engine support.
5. Remove or disconnect the following: Upper cover fasteners, Front cover vent hose, Right engine mount and bracket, Right front wheel, Right lower splash shield, Crankshaft balancer, Lower cover fasteners, Front cover
6. Rotate the crankshaft clockwise, as viewed from front of engine (normal rotation) until the camshaft sprocket's timing dowel pin holes align with the timing chain housing holes. The crankshaft sprocket mark should align with the engine mark. The crankshaft sprocket keyway should point upward and align with the cylinder bores centerline. This is the normal timed position.
7. Remove the timing chain guides.
8. Remove the timing chain tensioner.
   NOTE Be sure all the slack in the timing chain is above the tensioner assembly when removing it. CAUTION The tensioner plunger is spring loaded and could fly out causing personal injury.
9. Remove or disconnect the following: Timing chain, Camshaft sprockets

To install:

1. Install or connect the following: Camshaft sprockets. Torque the bolts to 52 ft. lbs. (70 Nm),
   Camshaft sprocket alignment pin through the camshaft sprockets holes into the timing chain housing holes to position the camshafts for timing.
2. If the camshafts are out of position and must be rotated more than 1 / 8 turn in order to install the alignment dowel pins, perform the following:
   1. Rotated the crankshaft 90 degrees clockwise off Top Dead Center (TDC) in order to give the valves adequate clearance to open.
   2. Once the camshafts are positioned and the dowels installed, rotate the crankshaft counterclockwise back to TDC.
      WARNING Do not rotate the crankshaft clockwise to TDC or valve and piston damage may occur.
      
3. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket.
   

   Fig. Timing chain and sprocket alignment positions-2.4L DOHC engine
   

4. Remove the alignment dowel pin from the intake camshaft. Using a dowel pin remover tool, rotate the intake camshaft sprocket counterclockwise enough to slide the timing chain over the intake camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the 2 camshaft sprockets will tighten.
   NOTE If properly timed, the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated.
5. Leave the alignment dowel pins installed.
6. With slack removed from chain between intake camshaft sprocket and crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain 1 tooth forward or rearward, remove slack and recheck the marks.
7. Tighten the chain housing to engine stud. The stud is installed under the timing chain. Torque it to 19 ft. lbs. (26 Nm).
8. Reload the timing chain tensioner as follows:
   1. Form a keeper from heavy gauge wire.
   2. Slightly, compress the shoe plunger and insert a small screwdriver into the access hole.
   3. Release the ratchet pawl and compress the plunger completely into the hole.
   4. Insert the keeper between the access hole and the blade.
9. Install or connect the following:
   Tensioner assembly to the chain housing. Torque the bolts to 89 inch lbs. (10 Nm). Tensioner shoe and retainer. Torque the bolts to 89 inch lbs. (10 Nm). NOTE Recheck plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.
10. Remove the alignment dowel pins. Rotate crankshaft clockwise 2 full rotations. Align the crankshaft timing mark with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly.
    WARNING If the engine is not correctly timed, severe engine damage could occur.
11. Install or connect the following: Timing chain guides, New seal into the front cover by lubricating the seal lip and tapping it into place, Front cover and gaskets. Torque the nuts and bolts to 106 inch lbs. (12 Nm), Crankshaft balancer. Torque the bolt to 129 ft. lbs. (175 Nm), Right front lower splash shield, Front wheel. Torque the nuts to 100 ft. lbs. (140 Nm), Right engine mount bracket. Torque the bolts to 81 ft. lbs. (110 Nm) plus an additional 90 degree turn, Right engine mount. Torque the bolt to 49 ft. lbs. (60 Nm), Upper cover vent hose
12. Remove the engine support.
13. Install or connect the following: Alternator. Torque the bolts to 37 ft. lbs. (50 Nm), Accessory drive belt, Coolant surge tank, Negative battery cable.
    
14. Refill the cooling system.
15. Start the engine and check for leaks.

This is on a 3.4L V6

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

Timing Chain and Sprockets REMOVAL & INSTALLATION 2.3L and 2.4L Engines The following tools will be required to perform this procedure:

• Camshaft sprocket timing alignment pins - J 36008 or equivalent
• Camshaft sprocket wrench - J 39579 or equivalent

2. Fig. 1: View of the DOHC engine "timed position'' - 2.3L and 2.4L engines
   Fig. 2: View of the SOHC engine "timed position'' - 2.3L engine
   
3. Remove the timing chain guides. There are usually three.
4. Raise and safely support the front of the vehicle.
5. Make sure all of the slack is above the tensioner. Gently pry off timing chain tensioner spring retainer, then remove the spring. NOTE: On the 2.3L engine two styles of tensioners are used. Early production engines will have a spring post and late production ones will not. Both styles are identical in operation and are interchangeable.
   
6. Remove the timing chain tensioner shoe retainer.
7. Make sure all the slack in the timing chain is above the tensioner assembly; remove the chain tensioner shoe. The timing chain must be disengaged from the wear grooves in the tensioner shoe in order to remove the shoe. Slide a suitable small prybar under the timing chain while pulling shoe outward.
8. If difficulty is encountered while removing chain tensioner shoe, proceed as follows:
   1. Lower the vehicle.
   2. Hold the intake camshaft sprocket with a camshaft sprocket wrench - J 39579 or equivalent holding tool and remove the sprocket bolt and washer.
   3. Remove the washer from the bolt and re-thread the bolt back into the camshaft by hand. The bolt provides a surface to push against.
   4. Remove intake camshaft sprocket using a 3-jaw puller in the 3 relief holes in the sprocket. NOTE: Do NOT try to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur.
      
9. Unfasten the tensioner assembly attaching bolts, then remove the tensioner. CAUTION
   The tensioner piston is spring loaded and could fly out causing personal injury. Use care when removing.
   
10. Matchmark the timing chain outer surface for reassembly purposes.
11. If equipped, remove the chain housing to block stud, which is actually the timing chain tensioner shoe pivot.
12. Remove the timing chain.
13. Inspect the parts for wear, then replace if necessary. Some scoring of the timing chain shoe and guides is normal. Clean the old sealant off of the bolt with a wire brush. Clean the threaded hole in the camshaft with a round nylon bristle brush. To install: WARNING
    Failure to following installation procedures can result in severe engine damage.
    
14. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. Install the sprocket retaining bolt and washer. Use an adhesive compound 12345493 or equivalent on the bolt. Tighten the bolt to 52 ft. lbs. (70 Nm), while holding the sprocket with tool J-36013, J 39579 or equivalent, if removed.
15. Install tool J 36800 or equivalent, through hole(s) in the camshaft sprocket(s) into the holes in the timing chain housing. This positions the camshafts for correct timing. Fig. 3: Placing the camshaft sprockets onto the marked surface of the camshaft
    
16. If the camshafts are out of position and must be rotated more than 1?8 turn in order to install the alignment dowel pins:
    1. The crankshaft must be rotated 90°clockwise off of TDC in order to give the valves adequate clearance to open.
    2. Once the camshafts are in position and the dowels installed, rotate the crankshaft COUNTERCLOCKWISE back to TDC. NOTE: Do NOT rotate the crankshaft clockwise to TDC, or valve and piston damage could occur. WARNING
       The side of the timing chain that was marked must be facing outward when installed.
       
17. For DOHC engines only, install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket.
18. Remove the alignment dowel pin from the intake (DOHC only) camshaft. Using dowel pin remover tool J 39579 or equivalent, rotate the intake (DOHC only) camshaft sprocket counterclockwise enough to slide the timing chain over the intake (DOHC only) camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the two camshaft sprockets will tighten. If properly timed, the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. Fig. 4: Place the timing chain over the exhaust camshaft and around the idler sprocket and around the crankshaft sprocketDOHC engines
    
19. Leave the alignment dowel pins installed.
20. Raise and safely support the vehicle.
21. With slack removed from chain between intake camshaft sprocket (camshaft sprocket for SOHC engines) and crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain one tooth forward or rearward, remove the slack and recheck the marks.
22. If equipped, tighten the chain housing to block stud. The stud is installed under the timing chain. Tighten to 19 ft. lbs. (26 Nm).
23. For vehicles through 1991, reload timing chain tensioner assembly to its "zero'' position as follows:
    1. Assemble restraint cylinder, spring and nylon plug into plunger. Index slot in restraint cylinder with peg in plunger. While rotating the restraint cylinder clockwise, push the restraint cylinder into the plunger until it bottoms. Keep rotating the restraint cylinder clockwise but allow the spring to push it out of the plunger. The pin in the plunger will lock the restraint in the loaded position.
    2. Install tool J-36589 or equivalent, onto plunger assembly.
    3. Install plunger assembly into tensioner body with the long end toward the crankshaft when installed.
24. For 1992-98 vehicles, reload timing chain tensioner assembly to its "zero'' position as follows:
    1. Form a keeper from a piece of heavy gauge wire. See the accompanying figure.
    2. Apply slight force on the tensioner blade to compress the plunger.
    3. Insert a small prybar into the reset access hole, then pry the racket pawl away from the ratchet teeth while forcing the plunger completely in the hole.
    4. Install the keeper between the access hole and the blade. Fig. 5: View of reloading the timing chain tensioner assembly to its "zero'' position - 1992-98 vehicles
       
25. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.
26. Install and tighten timing chain tensioner bolts. Tighten to 89 inch lbs. (10 Nm).
27. Install the tensioner shoe and tensioner shoe retainer. Remove the special tool J-36589, then squeeze the plunger assembly into the tensioner body to unload the plunger assembly.
28. Lower vehicle enough to reach and remove the alignment dowel pins.
29. Rotate crankshaft clockwise (normal rotation) two full rotations. Align the crankshaft keyway with the mark on the cylinder block, then reinstall the alignment dowel pins. The pins will slide in easily if the engine is timed correctly. WARNING
    If the engine is not correctly timed, severe engine damage could occur.
    
30. Install the timing chain guides and, if equipped, the crankshaft oil slinger.
31. Install the timing chain front cover. For details, please refer to the procedure located in this section.
32. Connect the negative battery cable, then start the engine and check for oil leaks.

2.3L and 2.4L Engines Before attempting to remove the timing chain, read the entire procedure.

1. Disconnect the negative battery cable.
2. Remove the timing chain front cover, as outlined earlier in this section.
3. Rotate the crankshaft clockwise, as viewed from the front of engine/normal rotation, until the camshaft sprocket timing dowel pin holes line up with the holes in the timing chain housing. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the "timed'' position. Fig. 8: The chain must be in the "timed'' position - 2.3L and 2.4L engines
   Fig. 9: Remove the timing chain guides
   
   
4. Remove the timing chain guides.
5. Raise and safely support the vehicle.
6. Make sure all of the slack in the timing chain is above the tensioner assembly, then remove the tensioner. The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a suitable prytool under the timing chain while pulling the shoe outward. WARNING
   Do NOT attempt to pry the socket off the camshaft or damage to the sprocket or chain housing could occur.
   
7. If difficulty is encountered in removing the chain tensioner shoe, remove the intake camshaft sprocket, as follows;
   1. Carefully lower the vehicle.
   2. Hold the intake camshaft sprocket with a suitable tool and remove the sprocket bolt and washer.
   3. Remove the washer from the bolt and rethread the bolt back into the camshaft by hand. The bolt provides a surface to push against.
   4. Remove the camshaft sprocket using a three-jaw puller in the three relief holes in the sprocket.
8. Unfasten the tensioner assembly retaining bolts, then remove the tensioner. NOTE: The timing chain and crankshaft sprocket MUST be marked before removal. If the chain or sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur.
   
9. Mark the crankshaft sprocket and timing chain outer surface for reassembly, then remove the chain.
10. Clean the old sealant off the bolt with a wire brush. Clean the threaded hole in the camshaft with a round nylon brush. Inspect the parts for wear and replace as necessary. Note that some scoring of the chain shoe and guides is normal. To install: WARNING
    Failure to follow this procedure may result in severe engine damage.
    
11. Position the intake camshaft sprocket onto the camshaft with the surface marked during removal showing.
12. Install the intake camshaft sprocket retaining bolt and washer, tighten to 52 ft. lbs. (70 Nm) while holding the sprocket with a suitable tool. Use GM sealant 12345493 or equivalent on the camshaft sprocket bolt.
13. Place GM tool J 36008, or equivalent camshaft aligning pins, through the holes in the camshaft sprockets into the holes in the timing chain housing. This positions the cams for correct timing.
14. If the camshafts are out of position and must be rotated more than 1?8 turn in order to install the alignment dowel pins, proceed as follows:
    1. The crankshaft MUST be rotate 90°clockwise off of TDC in order to five the valves adequate clearance to open.
    2. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to TDC. WARNING
       Do not rotate the crankshaft clockwise to TDC; valve or piston damage could result. NOTE: The side of the timing chain that was marked during removal must be showing when the chain is installed.
       
    
    
15. Place the timing chain over the exhaust camshaft sprockets, around the idler sprocket and around the camshaft sprocket.
16. Set the camshafts at the timed position and install the timing chain. Remove the alignment dowel pin from the intake camshaft. Using GM tool J 39579, rotate the intake camshaft sprocket counter clockwise enough to slide the timing chain over the intake camshaft sprocket. Release the camshaft sprocket wrench (J 39579 or equivalent). The length of the chain between the two camshaft sprockets will tighten. If properly timed, the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are NOT timed correctly and the procedure must be repeated.
17. Leave the alignment dowel pins installed. Raise and safely support the vehicle.
18. With the slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the timing marks on the crankshaft and cylinder block should be aligned. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and recheck the marks. Fig. 10: Timing chain assembly retaining bolts - 2.3L and 2.4L engines
    
    
19. Reload the timing chain tensioner assembly to its "zero'' position as follows:
    1. Form a keeper from a piece of heavy gauge wire, as shown in the accompanying figure.
    2. Apply slight force on the tensioner blade to compress the plunger.
    3. Insert a small prytool into the reset access hole, and pry the ratchet pawl away from the ratchet teeth while forcing the plunger completely in the hole.
    4. Install the keeper between the access hole and the blade. Fig. 11: Reloading the tensioner to its "ZERO'' position, then install to the chain housing
       
    
    
20. Install the tensioner assembly to the timing chain housing. Recheck the plunger assembly installation, it is correctly installed when the long end is toward the crankshaft. Install the tensioner retaining bolts; tighten to 89 inch lbs. (10 Nm).
21. Carefully lower the vehicle enough to reach and remove the alignment dowel pins. WARNING
    Severe engine damage could result if the engine is not properly timed.
    
22. Rotate the crankshaft clockwise (normal rotation) two full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall the alignment dowel pins. The pins will slide in easily if the engine is correctly timed.
23. Install the timing chain guides, then install the front (timing chain) cover.
24. Connect the negative battery cable.

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Item Part Number Description 1 — 40 Timing Chain/Belt Teeth 2 6256 Camshaft Sprocket , Front 3 — 43 Timing Chain/Belt Teeth 4 6306 Crankshaft Sprocket 5 6268 Timing Chain/Belt 6 6256 Camshaft Sprocket , Rear
Removal

1. Drain the cooling system. Refer to Section 03-03 for the procedure.
   

1. Disconnect the battery ground cable (14301) .
   

1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
   

1. If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
   

1. Remove the upper radiator hose bracket bolt.
   

1. Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
   

1. Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592) .
   

1. Remove the main wiring harness from the upper engine front cover (6019) .
   

1. Remove the eight upper engine front cover bolts and the upper engine front cover .
   

1. Raise and support the vehicle.
   

1. Remove the RH front wheel and tire assembly.
   

1. Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775) .
   

1. Use Strap Wrench 303-D055 (D85L-6000-A) or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
   

1. Remove the water pump pulley from the water pump (8501) .
   

1. Remove the crankshaft pulley (6312) . Refer to the procedure in this section.
   

1. Remove the five lower engine front cover bolts and the lower engine front cover .
   
2. Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
   
3. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.
   
4. Loosen the timing chain/belt tensioner nut.
   
5. Remove the timing chain/belt .
   
   
6. Installation
   NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned. NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts (6250) and the crankshaft (6303) . These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket .
   
   NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600) .
   
   Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprocket following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner .
   
   
   
   
   
   

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SPECIAL TOOLS REQUIRED (or equivalents)

• J-36008, Camshaft sprocket timing alignment pins.
• J-39579, Camshaft sprocket wrench.

CAUTIONS:

• The timing chain on the 1996 LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam Engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used.
• The timing chain and crankshaft sprocket MUST be marked so that they are reinstalled with the same side facing out at the time of reassembly.
• Failure to follow the removal and installation procedures could result in severe engine damage.

REMOVE OR DISCONNECT

1. Negative battery cable.
2. Front cover, refer to Timing Cover / Service and Repair .
3. Rotate crankshaft in clockwise direction until camshaft and crankshaft timing marks are aligned.
4. Timing chain guides.
5. Raise and support vehicle.
6. Ensure slack in timing chain is above tensioner assembly, then remove chain tensioner. The timing chain must be disengaged from grooves in tensioner shoe to permit removal of shoe. Position a suitable screwdriver under timing chain while pulling shoe outward. If difficulty is encountered in removing tensioner shoe, proceed as follows:

1. Lower vehicle, then while holding the intake camshaft sprocket with J-39579, remove sprocket bolt and washer.
2. Remove washer, then install bolt into camshaft by hand.
3. Position a suitable three jaw puller into intake camshaft sprocket relief holes and remove sprocket. CAUTION: Do NOT pry on camshaft sprocket as damage to sprocket or timing chain housing may result.

1. Tensioner assembly attaching bolts and tensioner assembly.
2. MARK CRANKSHAFT SPROCKET AND TIMING CHAIN outer surface for reassembly.
3. Timing chain.

INSTALL OR CONNECT

1. Intake camshaft sprocket onto camshaft with surface marked during removal showing.
2. Intake camshaft sprocket retaining bolt and washer, torque to 70 Nm (52 ft lbs) while holding the sprocket with J-39579 (if removed).
3. Timing pins, J-36008, through holes in camshaft sprockets into holes in timing chain housing to position camshafts for proper timing. If camshafts are out of position and must be rotated more that 1/8 turn to insert timing pins:

1. Crankshaft MUST be rotated 90°clockwise off of TDC in order to give the valves adequate clearance to open.
2. Once the camshafts are in position and the timing pins have been installed rotate crankshaft COUNTERCLOCKWISE to TDC. CAUTION: Do NOT rotate the crankshaft clockwise to TDC, valve or piston damage could occur.

1. Timing chain over exhaust camshaft sprocket, around idler sprocket and around crankshaft sprocket.
2. Set camshaft sprockets at timed position and install timing chain. Remove timing pin from intake camshaft. Using J-39579, rotate the intake camshaft sprocket counterclockwise until timing chain can be installed over sprocket. Release J-39579 after timing chain has been installed over sprocket. The length of chain between intake and exhaust camshaft sprockets should tighten. The timing pin should easily fit through intake camshaft sprocket timing hole into timing chain housing timing hole. If timing pin does not fully index, the camshafts are NOT timed correctly and the procedure MUST be repeated.
3. With timing pins installed, raise and support vehicle.
4. With slack removed from timing chain between intake camshaft sprocket and crankshaft sprocket, timing marks on crankshaft and engine block should be aligned. If the marks are not aligned, move timing chain one tooth forward or rearward to align marks. Remove slack and recheck marks.
5. Reload tensioner assembly to zero position as follows:

1. Form a keeper out of heavy gauge wire into a U-shaped piece with a half inch opening.
2. Apply slight force on tensioner blade to compress plunger.
3. Insert small screwdriver into reset access hole and pry rachet pawl away from ratchet teeth while forcing the plunger completely in the hole.
4. Install keeper between access hole and blade.

1. Tensioner assembly to chain housing and recheck plunger assembly installation, noting long end is toward crankshaft.
2. Tighten timing chain tensioner bolts to 10 Nm (89 in lbs) .
3. Lower vehicle to point where timing pins can be removed from camshaft sprockets.
4. Rotate crankshaft two revolutions in the clockwise direction. Align crankshaft keyway with the mark on cylinder block and reinstall timing pins through camshaft sprockets into housing timing holes. Timing pins should slide easily through timing holes. If timing pins cannot be inserted easily, repeat procedure to properly time engine. CAUTION: If the engine is not correctly timed, severe engine damage could occur.
5. Timing chain guides.
6. Engine front cover.
7. Negative battery cable.