Friday, October 7, 2011

How to replace timing CHAIN on 2004 Chevrolet Malibu?

PLEASE HELP.
I NEED TO REPLACE TIMING CHAIN ON MY CHEVY MALIBU.ITS 2004 MODEL.
BUT I DONT KNOW HOW TO ALIGN IT.PLEASE GIVING ME TIMING MARKS AS WELL AS TIMING CHAIN REMOVAL AND INSTALLATION INSTRUCTIONS:---

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OK.
But in Chevy Malibu, there is not one engine but various engines.
2.2L,3.3L,3.5L and 3.9L
I will give details for all.

Timing Chain Cover, Chain, Sprockets, & Seal




Removal & Installation



2.2L 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

    Click image to see an enlarged view
    Fig. Lining up the crankshaft sprocket mark with the colored link in the 5 o-clock position (2).


    Click image to see an enlarged view
    Fig. Aligning the intake camshaft sprocket mark with the colored link in the 2 o-clock position (1).


    Click image to see an enlarged view
    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.

    Click image to see an enlarged view
    Fig. Compressing the timing chain tensioner-2.2L 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

    Click image to see an enlarged view
    Fig. Lining up the crankshaft sprocket mark with the colored link in the 5 o-clock position (2).


    Click image to see an enlarged view
    Fig. Aligning the intake camshaft sprocket mark with the colored link in the 2 o-clock position (1).


    Click image to see an enlarged view
    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.

    Click image to see an enlarged view
    Fig. Compressing the timing chain tensioner-2.2L engine.
3.1L & 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system.
  4. Drain the engine oil.
  5. Recover the A/C system refrigerant.
  6. Install an engine support fixture.
  7. Remove or disconnect the following:

    Right engine mount assembly
    Accessory drive belt
    Air cleaner assembly
    Throttle body tube
    Power steering line at the pump
    Alternator and bracket
    Right front wheel
    Right inner fender well splash shield
    Right engine mount bracket
    Crankshaft balancer
    Drive belt tensioner
    Oil pan
    Crankshaft Position (CKP) sensor
    Coolant bypass pipe from the water pump and the intake manifold
    Lower radiator hose from the front cover outlet
    Front cover
  8. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment.
  9. Remove or disconnect the following:

    Camshaft sprocket and timing chain
    Crankshaft sprocket
    Timing chain damper

    Click image to see an enlarged view
    Fig. Timing chain and sprocket timing mark alignment
To install:
  1. Install or connect the following:

    Timing chain damper. Torque the bolts to 15 ft. lbs. (21 Nm).
    Crankshaft sprocket
  2. Be sure the crankshaft sprocket timing mark is pointing straight up.
  3. Install the timing chain over the camshaft sprocket and hold the sprocket in such a way, that the timing mark is pointing down, and the timing chain is hanging down off the sprocket.
  4. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. The sprocket will only fit on the camshaft if the dowel on the camshaft aligns with the hole in the sprocket.
  5. Verify that the marks are aligned (the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket will be in the 12 o'clock position).
  6. Torque the camshaft sprocket mounting bolt to 103 ft. lbs. (140 Nm).
  7. Lubricate the timing chain components with engine oil.
  8. Apply a thin bead of sealer around the gasket sealing area of the front cover.
  9. Install or connect the following:

    Front cover with a new seal and gasket. Torque the small bolts to 15 ft. lbs. (21 Nm) and the large bolts to 35 ft. lbs. (47 Nm).
    Radiator hose to the coolant outlet
    Coolant bypass pipe to the water pump and intake manifold
    CKP sensor
    Oil pan. Torque the bolts to 18 ft. lbs. (24 Nm) and the side bolts to 37 ft. lbs. (50 Nm).
    Crankshaft balancer. Torque the bolt to 76 ft. lbs. (103 Nm).
    Accessory drive belt tensioner. Torque the bolt to 40 ft. lbs. (54 Nm).
    Right engine mount bracket. Torque the bolts to 96 ft. lbs. (130 Nm).
    Right inner fender well splash shield
    Wheel
  10. Remove the engine support fixture.
  11. Install or connect the following:

    Alternator. Torque the front bolt to 37 ft. lbs. (50 Nm) and the rear bolt to 18 ft. lbs. (24 Nm).
    Power steering line
    Throttle body tube
    Air cleaner assembly
    Accessory drive belt
    Negative battery cable
  12. Refill the cooling system.
  13. Check the engine oil level.
    NOTE
    An oil and filter change is recommended.
  14. Start the engine and verify that there are no leaks.
3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Drain the cooling system.
  4. Drain the engine oil.
  5. Recover the A/C system refrigerant.
  6. Install an engine support fixture.
  7. Remove or disconnect the following:

    Right engine mount assembly
    Accessory drive belt
    Air cleaner assembly
    Throttle body tube
    Power steering line at the pump
    Alternator and bracket
    Right front wheel
    Right inner fender well splash shield
    Right engine mount bracket
    Crankshaft balancer
    Drive belt tensioner
    Oil pan
    Crankshaft Position (CKP) sensor
    Coolant bypass pipe from the water pump and the intake manifold
    Lower radiator hose from the front cover outlet
    Front cover
  8. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment.
  9. Remove or disconnect the following:

    Camshaft sprocket and timing chain
    Crankshaft sprocket
    Timing chain damper

    Click image to see an enlarged view
    Fig. Timing chain and sprocket timing mark alignment
To install:
  1. Install or connect the following:

    Timing chain damper. Torque the bolts to 15 ft. lbs. (21 Nm).
    Crankshaft sprocket
  2. Be sure the crankshaft sprocket timing mark is pointing straight up.
  3. Install the timing chain over the camshaft sprocket and hold the sprocket in such a way, that the timing mark is pointing down, and the timing chain is hanging down off the sprocket.
  4. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. The sprocket will only fit on the camshaft if the dowel on the camshaft aligns with the hole in the sprocket.
  5. Verify that the marks are aligned (the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket will be in the 12 o'clock position).
  6. Torque the camshaft sprocket mounting bolt to 103 ft. lbs. (140 Nm).
  7. Lubricate the timing chain components with engine oil.
  8. Apply a thin bead of sealer around the gasket sealing area of the front cover.
  9. Install or connect the following:

    Front cover with a new seal and gasket. Torque the small bolts to 15 ft. lbs. (21 Nm) and the large bolts to 35 ft. lbs. (47 Nm).
    Radiator hose to the coolant outlet
    Coolant bypass pipe to the water pump and intake manifold
    CKP sensor
    Oil pan. Torque the bolts to 18 ft. lbs. (24 Nm) and the side bolts to 37 ft. lbs. (50 Nm).
    Crankshaft balancer. Torque the bolt to 76 ft. lbs. (103 Nm).
    Accessory drive belt tensioner. Torque the bolt to 40 ft. lbs. (54 Nm).
    Right engine mount bracket. Torque the bolts to 96 ft. lbs. (130 Nm).
    Right inner fender well splash shield
    Wheel
  10. Remove the engine support fixture.
  11. Install or connect the following:

    Alternator. Torque the front bolt to 37 ft. lbs. (50 Nm) and the rear bolt to 18 ft. lbs. (24 Nm).
    Power steering line
    Throttle body tube
    Air cleaner assembly
    Accessory drive belt
    Negative battery cable
  12. Refill the cooling system.
  13. Check the engine oil level.
    NOTE
    An oil and filter change is recommended.
  14. Start the engine and verify that there are no leaks.
3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the cooling system.
  3. Remove the drive belt tensioner.
  4. Remove the oil pan.
  5. Remove the crankshaft balancer.
  6. Remove the crankshaft position actuator magnet.
  7. Remove the thermostat housing.
  8. Remove the water pump.
  9. Remove the engine front cover bolts.
  10. Remove the engine front cover.
  11. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
  12. Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).

    Click image to see an enlarged view
    Fig. 3.9L Engine timing mark alignment shown
  13. Remove the camshaft sprocket bolts.
  14. Remove the timing chain, camshaft, and crankshaft sprockets.
  15. Remove the timing chain tensioner bolts.
  16. Remove the timing chain tensioner.

    Click image to see an enlarged view
    Fig. 3.9L Engine timing chain tensioner removal
  17. Remove and discard the camshaft position actuator filter from the end of the camshaft.
    NOTE
    Always install a NEW camshaft position actuator filter anytime the camshaft position actuator is removed.



    Click image to see an enlarged view
    Fig. 3.9L Engine camshaft actuator filter (1)
To install:
  1. Install a new camshaft position actuator filter (1) to the end of the camshaft.
  2. Install the crankshaft sprocket.
  3. Apply prelube to the crankshaft sprocket thrust surface.
  4. Install the timing chain tensioner.
  5. Install the timing chain tensioner bolts and tighten to 15 ft. lbs. (21 Nm).
  6. Using the EN-47719, fully collapse the tensioner, and place the tensioner retaining pin into the retaining hole (1).

    Click image to see an enlarged view
    Fig. Using the EN-47719, to fully collapse the tensioner and installing retainer pin
  7. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
  8. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
  9. Align the timing mark on the camshaft gear (3) with the timing mark on top of the timing chain tensioner (4).
  10. Align the dowel in the camshaft sprocket with the dowel hole in the camshaft.
  11. Draw the camshaft sprocket onto the camshaft using the mounting bolts and tighten to 12 ft. lbs. (16 Nm).
  12. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
  13. Coat the crankshaft and camshaft sprockets with clean engine oil.
  14. Pry out the crankshaft front oil seal from the cover using a suitable tool.
  15. Lubricate the NEW oil seal with clean engine oil.
  16. Install the crankshaft front oil seal using J 35468 and a suitable tool.
  17. Install the new engine front cover gasket.
  18. Install the engine front cover.
  19. Add sealant to the bolts (1) in the locations pointed out in the graphic.

    Click image to see an enlarged view
    Fig. 3.9L Engine front cover, add sealant to (1) bolts shown
  20. Install the engine front cover.
  21. Install the engine front cover bolts and tighten to 18 ft. lbs. (25 Nm).
  22. Install the water pump.
  23. Install the thermostat housing.
  24. Install the crankshaft position actuator magnet.
  25. Install the crankshaft balancer.
  26. Install the oil pan.
  27. Install the drive belt tensioner.
  28. Fill and bleed the cooling system.
    NOTE
    An oil and filter change is recommended.
  29. Check the engine oil level.
  30. Start the engine and verify that there are no leaks.

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THANK YOU.
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