Drop 8.mm sprocket in timing chain area. how to get the sprocket out.

?
oil balance shaft? it is called the BSM


yes , RTM read the service manual,

https://eautorepair.net/Marketing/Default.asp

the 2 cams are set using a tool called locking wedge.
4 marks aligned 2 cam sprockets per the manual./

BSM WORDS ,INSTALL

There are two different Balance Shaft Module (BSM) to engine block bolts used. 180 mm bolts with a lock-patch on the threads or 185 mm bolts without lock-patch. Do not reuse the 180 mm bolts. Always discard 180 mm bolts after removing. Failure to replace these bolts can result in engine damage. The 185 mm bolts are reusable. Install the same length bolts that were removed and use either four new 180 mm bolts or four 185 mm bolts.
If chain was removed, align marks on crankshaft sprocket (2) and chain (1).
Align marks on crankshaft sprocket (2) and chain (1)

1. Align marks on oil pump sprocket (5) and chain (4).
2. Install chain on sprocket.
3. Pivot BSM assembly upwards and position on ladder frame.
4. Start BSM mounting bolts by hand.
5. Use a three step procedure when tightening BSM mounting bolts.
6. Tighten new 180 mm BSM mounting bolts as follows:
   
   1. Tighten to 11 ft. lbs. (15 Nm) in the sequence shown.
   2. Tighten to 24 ft. lbs. (33 Nm) in the sequence shown.
   3. Rotate bolts an additional 90° in the sequence shown.
7. Tighten 185 mm BSM mounting bolts as follows:
   
   1. Tighten to 11 ft. lbs. (15 Nm) in the sequence shown.
   2. Tighten to 22 ft. lbs. (29 Nm) in the sequence shown.
   3. Rotate bolts an additional 90° in the sequence shown.Remove tensioner pin 9703 (4).
      Remove tensioner pin 9703 (4)
      
      1. nstall oil pan.
      2. Fill with oil.
      3. Start engine and check for leaks.
      READ THE MANUAL PAY $20 LIKE ME.

double posted but this time the CAM pops up.
why not read the FSM first. ? linked below.
or alldata.com . log in and read.

here ill do a paste from JUST install PART chapter.
you are doing ALL THAT book free, REALLY?
https://www.techauthority.com/en-US/Pages/Home.aspx

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.
2. 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.
3. Position primary chain tensioner over oil pump and insert bolts into lower two holes on tensioner bracket. Tighten bolts to 250 inch lbs. (28 Nm).
4. Install right side chain tensioner arm. Install Torx®bolt. Tighten Torx®bolt to 250 inch lbs. (28 Nm). CAUTION The silver bolts retain the guides to the cylinder heads and the black bolts retain the guides to the engine block.
5. Install the left side chain guide. Tighten the bolts to 250 inch lbs. (28 Nm).
6. Install left side chain tensioner arm, and Torx®bolt. Tighten Torx®bolt to 250 inch lbs. (28 Nm).
7. Install the right side chain guide. Tighten the bolts to 250 inch lbs. (28 Nm).
8. 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 8429 to hold chains in place for installation.
9. Align primary chain double plated links with the timing mark at 12 o'clock on the idler sprocket.
10. Align the primary chain single plated link with the timing mark at 6 o'clock on the crankshaft sprocket.
11. Lubricate idler shaft and bushings with clean engine oil. NOTE The idler sprocket must be timed to the counterbalance shaft drive gear before the idler sprocket is fully seated.
12. Install all chains, crankshaft sprocket, and idler sprocket as an assembly . After guiding both secondary chains through the block and cylinder head openings, affix chains with a elastic strap or equivalent. This will maintain tension on chains to aid in installation. Align the timing mark on the idler sprocket gear to the timing mark on the counterbalance shaft drive gear, then seat idler sprocket fully . Before installing idler sprocket bolt, lubricate washer with oil, and tighten idler sprocket assembly retaining bolt to 25 ft. lbs. (34 Nm). NOTE It will be necessary to slightly rotate camshafts for sprocket installation.
13. Align left camshaft sprocket "L" dot to plated link on chain.
14. 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.
15. Remove Special Tool 8429, then attach both sprockets to camshafts. Remove excess oil from bolts, then Install sprocket bolts, but do not tighten at this time.
16. Verify that all plated links are aligned with the marks on all sprockets and the "V6" marks on camshaft sprockets are at the 12 o'clock position. CAUTION Ensure the plate between the left secondary chain tensioner and block is correctly installed.
17. Install both secondary chain tensioners. Tighten bolts to 250 inch lbs. (28 Nm). NOTE Left and right secondary chain tensioners are not common.
18. Remove all locking pins 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.
19. Using Special Tool 6958, Spanner with Adaptor Pins 8346, tighten left and right . camshaft sprocket bolts to 90 ft. lbs. (122 Nm).
20. Rotate engine two full revolutions. Verify timing marks are at the follow locations: ² primary chain idler sprocket dot is at 12 o'clock ² primary chain crankshaft sprocket dot is at 6 o'clock ² secondary chain camshaft sprockets "V6" marks are at 12 o'clock ² counter balancer shaft drive gear dot is aligned to the idler sprocket gear dot.
21. Lubricate all three chains with engine oil.
22. After installing all chains, it is recommended that the idler gear end play be checked. The end play must be within mm 0.004-0.010 inches (0.10-0.25). If not within specification, the idler gear must be replaced.
23. Install timing chain cover and crankshaft damper.
24. Install cylinder head covers. NOTE Before installing threaded plug in right cylinder head, the plug must be coated with sealant to prevent leaks.
25. Coat the large threaded access plug with Mopar® Thread Sealant with Teflon, then install into the right cylinder head and tighten to 60 ft. lbs. (81 Nm).
26. Install the oil fill housing.
27. Install access plug in left cylinder head.
28. Install power steering pump.
29. Fill cooling system.
30. Connect negative cable to battery.

wow no job stated.
04 (2.3L) ill take a wild guess and say, you might be fiddling the cam
and doing something there, new cam, new lifters, new chain, new head, ? what?
FSM means factory service manual, ever heard of one?

the FSM is just lousy 4 bucks why not read that first. and not mess it up.

https://suzukipitstopplus.com/Products/1004-2004-aerio-service-manual.aspx

you said SET, so i can only assume its all apart. right then
you want to Instal the chain and time it, right so here are the fsm steps
no photos. log in and read the FSM for that.

1. Check that match mark on crankshaft timing sprocket is in match with timing mark on lower crankcase.
2. Install crankshaft timing sprocket as shown in figure.
3. Apply oil to bush of idler sprocket and install idler sprocket and sprocket shaft.
4. Install first timing chain by aligning dark blue plate of first timing chain and match mark on idler sprocket.
5. Bring yellow plate of first timing chain into match with match mark on crankshaft timing sprocket.
6. Apply engine oil to sliding surface of timing chain tensioner and then install it as shown in figure. Tighten tensioner nut to 18 ft. lbs. (25 Nm).
7. With latch of tensioner adjuster No.1 returned and plunger pushed back into body, insert stopper into latch and body. After inserting it, check to make sure that plunger will not come out.
8. Install timing chain tensioner adjuster No.1. Tighten the timing chain tensioner adjuster No. 1 bolt to 8 ft. lbs. (11 Nm).
9. Pull out stopper from adjuster No.1.
10. Apply engine oil to sliding surface of timing chain guide No.1 and then install it. Tighten guide bolts to 6.5 ft. lbs. (9 Nm).
11. Check that dark blue and yellow plates of first timing chain are in match with match marks on sprockets respectively.
12. Install second timing chain as follows:
    • Check that match mark on crank timing sprocket is in match with timing mark on lower crankcase.
    • Check that arrow mark on idler sprocket faces upward.
    • Check that knock pins of intake and exhaust camshafts are aligned with timing marks on cylinder head.
    • Install second timing chain by aligning yellow plate of second timing chain and match marks on idler sprocket.
    • Install sprockets to intake and exhaust camshafts by aligning dark blue plate of second timing chain, match marks on intake sprocket and exhaust sprocket respectively. NOTE As an arrow mark is provided on both sides, camshaft timing sprocket has no specific installation direction.
      
      
      

• Install intake and exhaust camshaft timing sprocket bolts. To install it, fit a spanner to hexagonal part at the center of camshaft to hold it stationary. Tighten the camshaft timing sprocket bolt to 57.5 ft. lbs. (80 Nm).
• Push back plunger into tensioner body and hold it at the position by inserting stopper into body.
• Install timing chain tensioner adjuster No.2 with new gasket. Tighten the timing chain tensioner adjuster No. 2 bolts to 8 ft. lbs. (11 Nm) and No. 2 nut to 33 ft. lbs. (45 Nm).
• Pull out stopper from timing chain tensioner adjuster No.2.
• Turn crankshaft two rotations clockwise then align timing mark on crankshaft and timing mark on cylinder block.
• Check that timing marks of cylinder head and cylinder block are in match with match marks on sprockets respectively.
• Apply oil to timing chains, tensioner, tensioner adjusters, sprockets, and guides.
• Install timing chain cover. Reverse removal sequence to install timing chain cover noting the following points:
  
  • Apply sealant "A" and "B" to area as shown.
    
    • "A": Sealant 99000-31250
    • "B": Sealant 99000-31140
  • Apply sealant amount to the following areas.
    
    • "a": 0.12 inches (3mm)
    • "b": 0.08 inches (2mm)
    • "c": 0.24 inches (6mm)
    • "d": 0.63 inches (16mm)
    • "e": 0.55 inches (14mm)
    • "f": 2.56 inches (65mm)
    • "g": 2.87 inches (73mm)
    • "h": 0.16 inches (4mm)
  • Apply engine oil to oil seal lip, then install timing chain cover. Tighten bolts and nut to 8 ft. lbs. (11 Nm).
    NOTE Before installing timing chain cover, check that pin is securely fitted.
• • Before installing timing chain cover, check that pin is securely fitted.
• Install alternator belt idler pulley. Tighten nut to 30.5 ft. lbs. (42 Nm).
• Install alternator belt tensioner. Tighten bolts to 18.5 ft. lbs. (25 Nm).
• Install water pump pulley.
• Install A/C compressor bracket (if equipped). Tighten bracket bolts to 40 ft. lbs. (55 Nm).
• Install cylinder head cover with new gaskets and seal washers and tighten nuts to 8 ft. lbs. (11 Nm).
• Install oil pan.
• Install crankshaft pulley using pulley holder tool. Tighten the crankshaft pulley bolt to 108.5 ft. lbs. (150 Nm).
• Install engine assembly.
• Install all remaining components in the reverse order of the removal procedure.

did that cover it, surely not.
but if you get the FSM and read it or log in , you will not miss the photos and the complex sealing bs on this motor.

Procedure is pasted below. Please let me know if you have questions.
Removal & Installation2.2L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Drain the engine oil.
4. Remove or disconnect the following:
   NOTE The timing chain has 2 matching colored links and 1 uniquely colored link.
   Negative battery cable, PCV hose, Fuel line bracket, Ignition coil and module assembly Ground strap from camshaft cover, Camshaft cover, Front fender liner, Accessory drive belt Crankshaft balancer pulley, Accessory drive belt tensioner, Front cover-to-water pump bolt Remaining front cover bolts, Front cover
   
5. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link (2) at the 5 o-clock position.
6. Confirm that the INT diamond on the intake camshaft sprocket is aligned with the uniquely colored link at (1) the 2 o-clock position.
7. Confirm that the EXH triangle on the exhaust camshaft sprocket is aligned with the matching colored link (3).
8. Remove or disconnect the following:
   NOTE Use a 24 mm wrench to hold the camshafts to prevent them from turning.
   Timing chain tensioner, Fixed timing chain guide access plug, Fixed timing chain guide Upper timing chain guide, Exhaust camshaft sprocket, Timing chain tensioner guide Intake camshaft sprocket, Timing chain through the top of the cylinder head Crankshaft sprocket
   
   
   

   Fig. Lining up the crankshaft sprocket mark with the colored link in the 5 o-clock position (2).
   
   
   
   

   Fig. Aligning the intake camshaft sprocket mark with the colored link in the 2 o-clock position (1).
   
   
   
   

   Fig. Aligning the exhaust camshaft sprocket (3).
   

To install:

1. Install the crankshaft sprocket with the timing mark in the 5 o-clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head.
4. Route the timing chain around the crankshaft sprocket and line up the first marching colored link (2) with the timing mark on the crankshaft sprocket.
5. Install the exhaust camshaft sprocket with a new bolt loosely onto the exhaust camshaft.
6. Align the timing mark on the sprocket with the last matching colored (3).
7. If necessary, align the camshaft as follows:
   1. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft.
   2. Turn the crankshaft 45 degrees in either direction.
   3. Turn the intake camshaft to the appropriate location.
   4. Turn the crankshaft back to top dead center (TDC).
8. When the sprocket seats in on the camshaft, tighten the sprocket bolt hand tight.
9. Verify all of the colored links and the appropriate timing marks are still aligned.
10. Install the fixed timing chain guide. Tighten the bolts to 133 inch lbs. (15 Nm).
11. Install the upper timing chain guide. Tighten the bolts to 89 inch lbs. (10 Nm).
12. Using a 24 mm wrench to hold the camshafts, tighten the camshaft sprocket bolts 63 ft. lbs. (85 Nm) plus 30 degrees.
13. Measure the timing chain tensioner from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inches (72 mm) front end to end. A tensioner in the active state will measure 3.35 inches (85 mm) from end to end.
14. If the timing chain tensioner is not in the compressed state, perform the following steps:
    1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
    2. Install the bottom half of the Tensioner tool J-45027-2 into a vise.
    3. Install the notch end of the piston assembly into the bottom half of the tensioner tool.
    4. Using the top half of the Tensioner tool J-45027-1, turn the ratchet cylinder into the piston.
    5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore.
    
    
15. Install the timing chain tensioner assembly. Tighten to 66 ft. lbs. (75 Nm).
16. Release the timing chain tensioner by compressing it approximately 0.08 inches (2mm). Feed a rubber-tipped tool down through the cam drive chest to reset on the cam chain. Give the tool a sharp jolt diagonally downwards to release the tensioner.
17. Install the timing chain oiling nozzle.
18. Install the timing chain guide bolt access hold plug with silicone sealant on the threads. Tighten the plug to 59 ft. lbs. (90 Nm).
19. Install or connect the following:
    
    Camshaft cover. Tighten the bolts to 89 inch lbs. (10 Nm). Front cover with new gasket. Tighten the bolts to 18 ft. lbs. (25 Nm). Accessory drive belt tensioner. Tighten the bolts to 33 ft. lbs. (45 Nm). Crankshaft balancer pulley using a new bolt. Tighten the bolt to 74 ft. lbs. (100 Nm) plus 75 degrees. Accessory drive belt, Front fender liner, Ground strap to camshaft cover Ignition coil and module assembly, Fuel line bracket, Air intake assembly, Negative battery cable
20. Refill the cooling system to the correct level.
21. Refill the engine with oil to the correct level.
22. Start the engine and check for leaks.
    
    
    

    Fig. Compressing the timing chain tensioner-2.2L engine.
    

It is possible to have a mix match, if the machine sprocket is 3/8 and the bar nose sprocket was say .325 you will have problems, also if the gauge of the bar and chain are different from one another the chain could be tight in the bar.

If it is running loose for a long time and is worn then should be replaced as soon as
But if the tensioner has come loose which it shouldn't have then an inspection of the links will further tell you if it should be replaced.There are ways to inspect the timing chain.This is a rough guide.

Timing Chain and Sprockets Cleaning and Inspection

1. Clean the components with cleaning solvent.
   Caution Wear safety glasses in order to avoid eye damage.
   
   
2. Dry the components with compressed air.
   
   
   
3. Inspect the timing chain for binding or wear.
   
   
   
4. Inspect the camshaft and crankshaft sprockets for:
   • Worn teeth (1)
   • Damaged teeth (2)
   • Chipped teeth (3)
   • Worn valleys between the sprocket teeth
   
   
   
   
5. Inspect the crankshaft sprocket keyway for wear.
6. Inspect the crankshaft sprocket oil pump drive splines for wear.
   
   
   
7. Inspect the chain guide (232) for the following conditions:
   • Loose metal inserts (1)
   • Cracking (2) in the chain contact area
   • Excessive grooves (3) in the chain contact area Grooves 1 mm (0.040 in) or less in depth are to be considered normal wear.

Getting the timing chain back on these engines can be tricky and requires more than just a diagram to get right. Here is how the timing chain should be reinstalled. Keep in mind that this engine can cause damage to the valves if the timing chain has any problems while the engine is running so it may not be a bad idea to setup the timing system as follows and do a compression test to make sure that everything is in order there.
Install the crankshaft sprocket with timing mark at the 5 o'clock position. Lower the timing chain through the opening in the top of the cylinder head. Carefully ensure that the chain goes around both sides of the cylinder block bosses (See 1 & 2 in picture): http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412535.gif

Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position. Hand tighten a NEW intake camshaft sprocket bolt. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond: http://gsi.xw.gm.com/image_en_us/gif/000/000/466/466558.gif

Install the timing chain tensioner guide through the opening in the top of the cylinder head. Tighten the timing chain tensioner guide bolt to 10 N·m (89 lb in): http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412160.gif

Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position: http://gsi.xw.gm.com/image_en_us/gif/000/000/466/466570.gif

Ensure the timing marks and the colored links (1,2,3) are correctly aligned: http://gsi.xw.gm.com/image_en_us/gif/000/002/003/2003412.gif

Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft. Hand tighten the NEW exhaust camshaft sprocket bolt: http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412536.gif

Install the fixed timing chain guide. Tighten the fixed timing chain bolts to 10 N·m (89 lb in): http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412165.gif

Apply sealant, GM P/N 12378521 (Canadian P/N 88901148) compound to thread and install the timing chain guide bolt access hole plug. Tighten the chain guide plug to 90 N·m (66 lb ft): http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412164.gif

Install the timing chain upper guide. Tighten the timing chain upper guide bolts to 10 N·m (89 lb in): http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412167.gif

Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.

****If the timing chain tensioner is not in the compressed state, perform the following steps. Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Set the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston: http://gsi.xw.gm.com/image_en_us/gif/000/000/797/797246.gif

Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint free cloth. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end repeat the steps required to return it to it's compressed state above.

Install the timing chain tensioner. Tighten the timing chain tensioner to 75 N·m (55 lb ft). Use a suitable tool with a rubber tip on the end. Feed the tool down through the camshaft drive chant to rest on the timing chain. Then give a sharp jolt diagonally downwards to release the tensioner: http://gsi.xw.gm.com/image_en_us/gif/000/000/412/412158.gif

Use a 24 mm wrench to hold the camshaft. Tighten the NEW camshaft bolts to 85 N·m (63 lb ft) plus 30 degrees: http://gsi.xw.gm.com/image_en_us/gif/000/000/630/630311.gif

5.0L and 5.7L Engines To Remove:

1. Remove the crankshaft balancer.
2. Drain the cooling system.
3. Remove the water pump.
4. Drain the engine oil.
5. Remove all engine oil pan fasteners except two nuts at rear of engine.
6. Separate the engine oil pan from the front cover.
7. Disconnect the crankshaft position (CKP) sensor wire.
   
   
8. Remove engine front cover.
   
   
9. Pry the oil seal from the front cover.
10. Inspect the front cover seal area and crankshaft balancer seal area for damage.
    
    
11. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned.
12. Remove the crankshaft position sensor reluctor ring.
    
    NOTE: Free play on the slack side of the camshaft timing chain must measure less than 0.43 inch (11Mm) or timing chain and sprockets must be replaced.
    
13. Remove the camshaft sprocket bolts.
14. Remove the camshaft sprocket.
15. Remove the camshaft timing chain. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
    
    
    
16. Remove the crankshaft sprocket using J 5825-A.
17. Remove the crankshaft balancer woodruff keys (if required).

To Install:

1. Install the crankshaft balancer woodruff keys into the crankshaft.
2. Align the crankshaft sprocket keyway with the crankshaft balancer woodruff key. WARNING
   Wear eye protection when installing crankshaft sprocket.
   
   
   
3. Use J 5590 to install crankshaft sprocket.
4. Install the camshaft sprocket and camshaft timing chain.
   
   
5. Ensure that the crankshaft sprocket alignment mark is in the 12 o'clock position and the camshaft sprocket alignment mark is at the 6 o'clock position.
6. Install the camshaft sprocket bolts and tighten the camshaft sprocket bolts;
   • Torque to: 18 ft. lbs. (25 Nm)
7. Install the crankshaft position sensor reluctor ring until completely seated against crankshaft sprocket. NOTE: The composite type engine front cover and seal must not be reused. Always install a new engine cover with a new seal.
   
8. Install new engine front cover and bolts.
   • Torque bolts to: 106 in. lbs. (12 Nm)
9. Clean sealer from corners of oil pan gasket where it meets the engine front cover.
   
   
10. Apply a 0.196 in (5 mm) bead of adhesive, GM P/N 12346141 or equivalent, 1.0 in (25 mm) long to the engine front cover to engine block junction.
11. Install oil pan bolts.
    • Torque bolts to: 106 in. lbs. (12 Nm)
12. Tighten oil pan nuts.
    • Torque bolts to: 18 ft. lbs. (25 Nm)
13. Connect the crankshaft position sensor wire.
14. Install the water pump.
15. Install the crankshaft balancer.
16. Fill the engine to the proper level with oil.
17. Fill the engine to the proper level with coolant.
18. Test drive the vehicle to confirm the repairs.

1998-2003 To Remove:

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

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

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

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.