Sunday, July 21, 2013

2004 Pontiac grand Prix timing chain Installation

How To Install Timing Chain On Pontiac 5.3 L Engine 


Before Getting on with timing chain Assembly instructions,please refer how to Disassemble old worn out faulty timing chain.


Pontiac Timing Chain Installation is as follows:

  1. Install the key into the crankshaft keyway, if previously removed.
  2. Tap the key into the keyway until both ends of the key bottom onto the crankshaft.
  3. Install the crankshaft sprocket onto the front of the crankshaft. Align the crankshaft key with the crankshaft sprocket keyway.

    Pontiac crankshaft sprocket assembly for installing timing chain

    Fig. Using the J 41665, install the crankshaft sprocket-5.3L engine
  4. Using the J 41665, install the crankshaft sprocket onto the crankshaft until fully seated against the crankshaft flange.
  5. Rotate the crankshaft sprocket until the alignment mark is in the 12 o'clock position.
  6. Install the timing change guide and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
    NOTE
    Properly locate the camshaft sprocket locating pin with the camshaft sprocket alignment hole. The sprocket teeth and timing chain must mesh. The camshaft and the crankshaft sprocket alignment marks MUST be aligned properly. Position the camshaft sprocket alignment mark in the 6 o'clock position.



    Click image to see an enlarged view

    Fig. With the chain dampener properly installed, the heads of the bolts (231) should install to flush or below the face of the guide (232)-5.3L engine


    Pontiac timing chain installation mark

    Fig. Timing mark alignment-5.3L engine
  7. Install the camshaft sprocket and timing chain. If necessary, rotate the camshaft or crankshaft sprockets in order to align the timing marks.
  8. Install the camshaft sprocket bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  9. Inspect the camshaft and crankshaft sprockets for proper timing mark alignment.
  10. Install the oil pump.
    NOTE
    Do not reuse the crankshaft oil seal or front cover gasket. Do not apply any type of sealant to the front cover gasket (unless specified). The special tool in this procedure is used to properly center the front crankshaft front oil seal. All gasket surfaces should be free of oil or other foreign material during assembly. The crankshaft front oil seal MUST be centered in relation to the crankshaft. An improperly aligned front cover may cause premature front oil seal wear and/or engine oil leaks.
  11. Apply a 5 mm (0.20 in.) bead of sealant GM P/N 12378577 or 12346141 (Canadian P/N 89022195) or equivalent 20 mm (0.80 in.) long to the oil pan to engine block junction.
  12. Install the front cover gasket and cover.
  13. Install the front cover bolts until snug. Do not overtighten.
  14. Install the oil pan-to-front cover bolts until snug. Do not over tighten.

    Pontiac timing chain installing front cover

    Fig. Install the J 41476 to the front cover-5.3L engine
  15. Install the J 41476 to the front cover.
  16. Align the tapered legs of the J 41476 with the machined alignment surfaces on the front cover.
  17. Install the crankshaft balancer bolt until snug. Do not overtighten. Tighten the oil pan to front cover bolts to 18 ft. lbs. (25 Nm). Tighten the engine front cover bolts to 18 ft. lbs. (25 Nm).
  18. Remove the J 41476.
  19. Install a NEW crankshaft front oil seal.
    NOTE
    The used crankshaft balancer bolt will be used only during the first pass of the balancer installation procedure. Install a NEW bolt and tighten as described in the second, third and forth passes of the balancer bolt tightening procedure. The crankshaft balancer installation and bolt tightening involves a four stage tightening process. The first pass ensures that the balancer is installed completely onto the crankshaft. The second, third, and forth passes tighten the new bolt to the proper torque.


    NOTE
    The balancer should be positioned onto the end of the crankshaft as straight as possible prior to tool installation.
  20. Position the crankshaft balancer onto the end of the crankshaft.
  21. Using tool J 41665, install the crankshaft balancer.
    1. Assemble the threaded rod, nut, washer and installer. Insert the smaller end of the installer into the front of the balancer.
    2. Use a wrench and hold the hex end of the threaded rod.
    3. Use a second wrench and rotate the installation tool nut clockwise until the balancer is started onto the crankshaft.
    4. Remove the tool and reverse the installation tool. Position the larger end of the installer against the front of the balancer.
    5. Use a wrench and hold the hex end of the threaded rod.
    6. Use a second wrench and rotate the installation tool nut clockwise until the balancer is installed onto the crankshaft.
    7. Remove the balancer installation tool.

  22. Install the USED crankshaft balancer bolt. Tighten the USED bolt to 330 Nm (240 ft. lbs.).
  23. Remove the USED crankshaft balancer bolt.
    NOTE
    The nose of the crankshaft should be recessed 2.4-4.48 mm (0.094-0.176 in.) into the balancer bore.
  24. Measure for a correctly installed balancer. If the balancer is not installed to the proper dimensions, install the J 41665 and repeat the installation procedure.
  25. Install a NEW crankshaft balancer bolt. Tighten the bolt a first pass to 37 ft. lbs. (50 Nm). Tighten the bolt a second pass to 140 degrees.
  26. Remove the flywheel holding tool from the block and flywheel.
  27. Install the transmission bellhousing bolt located at approximately the 10 o'clock position when looking from the rear of the engine. Tighten the bolt to 75 Nm (55 ft. lbs.).
  28. Raise and properly position the frame and install the frame to body bolts. Refer to Engine Removal & Installation.
  29. Install the frame to radiator braces.
  30. Install the front lower air deflector. Connect the intermediate steering shaft to the steering gear.
  31. Install the stabilizer shaft link lower nuts. Connect the transaxle cooler lines to the transaxle.
  32. Remove the engine support fixture.
  33. Install the front fender splash shield.
  34. Install the starter motor.
  35. Install the air cleaner upper housing.
  36. Install the accessory drive belt.
  37. Install the engine mount strut. Refer to Engine Removal & Installation.
  38. Install the right front tire and wheel assembly.
  39. Install the coolant pump manifold.
  40. Inspect the CMP sensor O-ring seal for cuts or damage. If the seal is not cut or damaged, it may be reused.
  41. Lubricate the O-ring seal with clean engine oil.
  42. Install the O-ring seal onto the CMP sensor.
  43. Install the CMP sensor and bolt from the front cover. Tighten the bolt to 12 Nm (106 inch lbs.).
  44. Position the belt tensioner and install the bolt. Tighten the bolt to 37 ft. lbs. (50 Nm).
  45. Install the power steering pump.
  46. Install the generator.
  47. Perform the crankshaft position (CKP) system variation learn procedure.
    1. Install a scan tool.
    2. Monitor the engine control module (ECM) for DTCs with a scan tool.
    3. Select the crankshaft position (CKP) variation learn procedure with a scan tool.
    4. The scan tool instructs you to perform the following:

      Accelerate to wide open throttle (WOT).
      Release throttle when fuel cut-off occurs.
      Observe fuel cut-off for applicable engine.
      Engine should not accelerate beyond calibrated RPM value.
      Release throttle immediately if value is exceeded.
      Block drive wheels.
      Set parking brake.
      DO NOT apply brake pedal.
      Cycle ignition from OFF to ON.
      Apply and hold brake pedal.
      Start and idle engine.
      Turn A/C OFF.
      Vehicle must remain in Park or Neutral.
      The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: CKP sensors activity--If there is a CKP sensor condition, refer to the applicable DTC that set. Camshaft position (CMP) sensor activity--If there is a CMP sensor condition, refer to the applicable DTC that set. Engine coolant temperature (ECT)--If the ECT is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
    5. Enable the CKP system variation learn procedure with a scan tool.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.
    6. Accelerate to WOT.
    7. Release when the fuel cut-off occurs.
    8. Test in progress
    9. The scan tool displays Learn Status: Learned this ignition.
    10. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully.
    11. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set:

      A CKP sensor replacement
      An engine replacement
      An ECM replacement
      A harmonic balancer replacement
      A crankshaft replacement
      Any engine repairs which disturb the CKP sensor relationship.

max