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Timing Chain & Sprockets: Installation

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Retracting Tensioner
GC0004018Courtesy of DAIMLERCHRYSLER CORP.
1 - TENSIONER
2 - TENSIONER PIN SPECIAL TOOL # 8514
  1. If tensioner (1) assembly is being replaced, install tensioner and mounting bolts. Torque bolts to 28 N.m (250 in. lbs.).
  2. Retract tensioner (2) if required.
    Fig 2: 5.7L/6.1L Timing Mark Alignment
    GC0004019Courtesy of DAIMLERCHRYSLER CORP.
    1 - Chain Tensioner
    2 - Camshaft Sprocket
    3 - Crankshaft Sprocket
    CAUTION: The timing chain must be installed with the single plated link aligned with the dot and or paint marking on the camshaft sprocket. The crankshaft sprocket is aligned with the dot and or paint marking on the sprocket between two plated timing chain links.
    CAUTION: The camshaft pin and the slot in the cam sprocket must be clocked at 12:00. The crankshaft keyway must be clocked at 2:00. The crankshaft sprocket must be installed so that the dots and or paint marking is at 6:00.
  3. Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores.
  4. Place timing chain around both sprockets.
  5. Lift sprockets and chain (keep sprockets tight against the chain in position as shown in Fig 2).
  6. Slide both sprockets (2,3) evenly over their respective shafts and check alignment of timing marks.
  7. Install the camshaft bolt. Tighten the bolt to 122 N.m (90 ft. lbs.) torque.
    Fig 3: Tensioner Pin
    GC0004017Courtesy of DAIMLERCHRYSLER CORP.
    1 - Pin
    2 - Tensioner
  8. Remove tensioner pin. (1)   Again, verify alignment of timing marks.
    Fig 4: Remove/Install Oil Pump
    GC0003966Courtesy of DAIMLERCHRYSLER CORP.
  9. Install the oil pump (Refer to ENGINE/LUBRICATION/OIL PUMP - INSTALLATION) .
  10. Install the oil pan and pick up (Refer to ENGINE/LUBRICATION/OIL PAN - INSTALLATION) .
    Fig 5: Front Cover Slide Bushings
    GC0003967Courtesy of DAIMLERCHRYSLER CORP.
  11. Install the timing chain cover (Refer to ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - INSTALLATION ).
  12. Refill engine oil.
  13. Fill cooling system (Refer to COOLING - STANDARD PROCEDURE) .
  14. Connect battery negative cable.
  15. Start engine and check for oil and coolant leaks.
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