Timing Chain Replacement - 2006 LY7 V-6 3.6L

12-01-2011, 12:22 PM
My 2006 SRX has the 3.6L V-6 engine, RPO Code LY7 (also known as the "High Feature, HFV6 and Alloytec). I have driven it since new, about 161K miles.

About a year and a half ago, it started getting very noisy at idle - a constant noise, somewhere in pitch between a whine and a roar. Like a bad bearing.

Then it started rattling, like the lifters had low oil, for about 5 seconds at startup. The noise was concentrated on the front of the engine, and did not seem to be coming from the camshaft covers. I only had the noise, no check engine lights (CELs).

The weak link (no pun intended) on these engines is the oil life interval and how it affects the primary timing chain. Many owners (CTS and other GM products use a similar engine) claim to have experienced noise and CELs associated with the elongation of the primary timing chain due to excessive wear. Some claim to have chain failures, with resulting valve to piston contact and damage. As noted by the next 2 posts, GM instituted a Customer Satisfaction program to re-program the engine oil life monitor.

I finally got around to disassembling the engine, and confirmed that the timing chain had elongated, had excessively worn the timing chain guides. The noise was likely from a combination of the chain slapping against the chain guides and tensioner shoes, and the worn teet on the primary chain gears.

This thread is intended to document for others how to go about making this repair. I have essentially done a "core dump" of pictures and information at my SRX's website, srxturnsignals.shutterfly.com.

To start with, let's familiarize ourselves with the LY7 engine. Here is what it looks like in the SRX (the CTS has a different oil pan):

http://im1.shutterfly.com/media/47a1cf11b3127ccefee9ec6659e800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D720/ry%3D480/

In this writeup I will try to use the standard naming convention, where the front of an engine is the pulley side, regardless of its orientation in the vehicle, and the back of the engine is the flywheel side. In a RWD vehicle with typical longitudinal engine placement, this should'nt cause an issue, but this same basic engine is used in FWD vehicles as well. So the right bank is on your left hand, if you are standing at the front of the car, looking to the rear.

Also, cylinders are numbered, from front to back, 1, 3, 5 on the right bank, 2, 4, 6 on the left bank. Firing order is 1, 2, 3, 4, 5, 6.

My engine looks somewhat different, in that I have a factory-optioned towing package that includes heavy-duty cooling. So I have a different setup on the front, and I don't have the idler pulley between the harmonic balancer and the ac compressor.

Here is another view - it will help you understand some of the hoses, lines and nuts that need to be removed from the backside:

http://im1.shutterfly.com/media/47a1cf11b3127ccefee88a1af8db00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D720/ry%3D480/

Here is a front view:

http://im1.shutterfly.com/media/47a1cf11b3127ccefee8abbf39c600000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D720/ry%3D480/

OK, next post we will start disassembly, with the ultimate goal of removing the front engine cover (the timing cover) to expose the timing chain.

12-01-2011, 02:10 PM
FYI, a recall has been issued to reprogram pcm with new oil life calibrations.

Thanks, but to be clear, as I understand it (and I am pretty sure I am right), it is not a recall, which has a very specific legal definition, but a Customer Satisfaction Program (No. 10287), and does not apply to the 2004-2006 model year SRXs. Customers to whose vehicles it does apply have until February 28, 2013 to have their vehicles reprogrammed for free.

12-01-2011, 02:14 PM
OK, back on track:

Jack it up:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd78ce511c00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove the lower deflector:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefca16fb03500000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Drain the coolant (writing says have a splash shield ready, this is not a petcock):

http://im1.shutterfly.com/media/47a1cc20b3127ccefe97754a4df800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 02:17 PM
Remove the strut bar:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd2501905500000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc56eb716200000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove the engine cover (just pulls up after removing oil and ps reservoir caps):

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc0ee1714400000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc2235718600000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove the air cleaner and duct:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc2cd2716600000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefcd2c9710200000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 02:26 PM
Remove the fan shroud and cooling fan with bracket (mine has heavy duty cooling option):

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3cb061a8600000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Four 10mm head bolts, the trickiest one is just above the ABS unit on lower right side of vehicle. Use a 1/4 drive extension and a impact (ball and socket) style u-joint:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefceaa7717000000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Fan bracket comes out with shroud, together. Do not disconnect fan from clutch:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee369169bf700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefdfda211aa00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd95ef90e300000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

The fan drive has an interesting coupling to the harmonic balancer - bushings and studs, no tool required to separate:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd2661519c00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 02:50 PM
Disconnect brake booster hose to intake manifold:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefda46bd0e700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove PCV fresh air hose from intake duct and left cam cover:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc91fa318800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd95ab90a700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove dirty air hose from left cam cover and intake manifold inserts (left and right):

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc7aacf00300000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove and displace evap purge solenoid valve:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd70d2510400000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Disconnect electrical connectors:

http://im1.shutterfly.com/media/47a1cc20b3127ccefe9748740d4000000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefca9f1b0af00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 03:10 PM
Now time to remove the intake manifold (IM).

Remove insulator for intake manifold tuning valve:

http://im1.shutterfly.com/media/47a1cf11b3127ccefee8599c399c00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

It's a no-see-um 13mm head nut, attached to a ground stud (so be careful the stud remains tight). You can do as I and others have done and loosen the nut, but do not remove, and then tear the insulator:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd619a11dc00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc8731314800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Disconnect the drive-by-wire throttle body at front and move the retainer down:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3780edb7f00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefcc7feb09700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee27940bbe500000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

I didn't get a closeup shot of it, but the main IM harness connector is a purple one, sitting on top of the right cam cover.

Remove the IM brace (leave the engine cover retaining ball stud alone):

http://im1.shutterfly.com/media/47a1cf06b3127ccefee27ed3fbed00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc2501b01900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

And now the IM retaining bolts. The IM consists of an upper and lower section. To do the timing chain you remove both as an assembly. To do spark plugs, just remove the upper.

http://im1.shutterfly.com/media/47a1cc20b3127ccefe97db074de200000010O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

I'll sometimes start with the hardest bolt first. In this case, its the rear one. It is below the black MAP sensor, almost straight down from the bend in the manifold:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc6532313a00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefcfb4b310c00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefce297714400000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Use an extension to get to it:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd647051ac00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

The front one is less hidden:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc364171f800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Then remove the remaining four bolts and disconnect the main IM harness.

12-01-2011, 03:17 PM
Set the IM assembly, with the fuel line attached, on the right cam cover/ strut tower (for access to the fuel line connector), and remove the locking clip:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefcf8a0717e00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd5a3ed0cd00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Get a non-glass container (do as I say not as I do), a fire extinguisher, a non-glass-bulb drop light, a no-smoking environment, eye protection, some common sense, and a 3/8" GM fuel line disconnector (the wrench is an easy sizing method). Depressurize by depressing the schraeder valve, covered with a cloth:

http://im1.shutterfly.com/media/47a1cf02b3127ccefefac970d95b00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefacf68587000000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefb9fc478b800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

A fair amount of gasoline comes out. Dispose of responsibly. You do not have to remove the injectors from the injector rail or the IM.

Remove the IM assembly and set in a safe place:

http://im1.shutterfly.com/media/47a1cf02b3127ccefefb3be278cc00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefbbecbb90f00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefacf3a582200000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 03:29 PM
Remove the water outlet with upper radiator hose:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefdb3b690a900000040O38IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D3/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc11aa319800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefcd435f0cd00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove the alt / wp belt:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3f870db4100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove water pump pulley:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefde45dd0f100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

If you didn't drop any of the last 6 bolts into an intake port, now would be a good time to cut a piece of cardboard and tape it in place so you don't:

http://im1.shutterfly.com/media/47a1cf02b3127ccefefb3bb2789c00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 03:43 PM
For the sake of clarity I am posting somewhat out of order i actually disassembled it, as long as it doesn't make a difference. So you might have noticed the ps reservoir and pulley had already been removed by the time of that last picture. If you did, Waldo points for you.

Remove the ps / ac belt:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3bc5adb4900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Remove the ps reservoir, but do not connect the ps lines to it:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee297abbb7900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc61ec31e600000050O28IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D2/rx%3D550/ry%3D400/

Remove the ps pulley:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefdd861d0d300000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefdc86a51e000000040O38IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D3/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd53fe909100000040O38IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D3/rx%3D550/ry%3D400/

Remove the ps / ac belt tensioner (you don't remove the alt / wp belt tensioner):

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc8e6cf0b900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 04:07 PM
While we are working on the ps, to free the front (timing chain) cover from the ps bracket, you need only remove one bolt, and loosen the second one:

http://im1.shutterfly.com/media/47a1cf11b3127ccefee84cca795800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefaa203998500000050O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

It took some doing to locate that rear/ bottom bolt, and finally did so with a short double-headed 1/4"x3/8" drive ratchet and my ubiquitous impact (ball and socket) u-joint (I have one in 1/4", 3/8" and 1/2" sizes). For clearance, I used the 1/4" ujoint, a 1/4" to 3/8" adaptor, and a 3/8" 15mm (I think) socket.

It helped to disconnect the oil pressure sensor:

http://im1.shutterfly.com/media/47a1cf02b3127ccefefba2e3b92900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 04:09 PM
OK, more to come. That's probably it for a while.

12-01-2011, 06:24 PM
Amazing post, credit to you tackling this number one, number two, it must have taken as much time to take and post the pics as doing the work, better man than I. !!! You disconnected the battery of course?

12-01-2011, 09:16 PM
Amazing post, credit to you tackling this number one, number two, it must have taken as much time to take and post the pics as doing the work, better man than I.

Yeah, I have a lot of pics collected in researching the job so that the downtime would be as small as possible. But posting and writing, yeah, that's a part-time job in itself. Good thing I love writing and teaching.

You disconnected the battery of course?

lolz. Went back through the pics - apparently I pulled the manifold without disconnecting the battery. But yeah, once you do the alternator, you want to disconnect the battery.

12-01-2011, 09:38 PM
Now do the other side - remove the alt bracket. There is no need to and you should not disconnect the alternator electrical connections, nor remove the alternator from the bracket. Nor do you remove the tensioner from the bracket.

Just remove the clip on the bracket that holds the water pipe close, and remove the bracket bolts. Get at the rear one from below the alternator. AND DON'T FORGET TO DISCONNECT THE BATTERY FIRST:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee26b9bbb3700000010O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cc20b3127ccefe961f5eeca500000010O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf11b3127ccefee8bbad39dc00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefb9454b98500000040O38IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D3/rx%3D550/ry%3D400/

12-01-2011, 09:48 PM
Now remove the ECM bracket (actually, I may have done this before the alternator, but shouldn't be a biggie). To assure the intergrity of the ECM connectors, and the ECM's ground to the bracket, we are removing the bracket and displacing it. Do not remove the ECM connectors or the ECM from the bracket. The rearmost bolt, on the side, has a clip in front of it that also has a 10mm head bolt. Don't confuse the two, but it might make it easier to remove the clip bolt first.

http://im1.shutterfly.com/media/47a1cf05b3127ccefee58543f29100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cc20b3127ccefe96c4c42dfa00000010O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cc20b3127ccefe96ec9fac8500000010O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefa479058cc00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Clip bolt:

http://im1.shutterfly.com/media/47a1cf02b3127ccefefb09bb788c00000040O38IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D3/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf02b3127ccefefaf299993700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 10:20 PM
Now the cam covers and coils. Disconnect the coils and carefully pry back the harness retainer:

Coil connector locked:
http://im1.shutterfly.com/media/47a1cf01b3127ccefefc19f631c000000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Coil connector unlocked:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefd715e111000000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee31a0c5a7c00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Don't forget the rear bolt:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3ec84dbbf00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

You can remove the cover with the coils just loosened, or take the coils out entirely. I suggest numbering them with a silver sharpie first.

http://im1.shutterfly.com/media/47a1cf06b3127ccefee2ce287a7e00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/
The right side harness protector has these clips that slide off:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee29cc6fb8900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3e050db6d00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3402cdb4100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 11:04 PM
Now the spark plugs.

Go to 'Vatozone and get a deep spark plug wrench like this one:


http://im1.shutterfly.com/media/47a1cf06b3127ccefee3b7261a9800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Plugs have 161K on them, probably running too rich and varnished engine. New one for comparison:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee219733ad600000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee33de49b2f00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3c6445a5a00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3b8aadbbb00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-01-2011, 11:27 PM
Now time to remove the front cover.

First, the harmonic balancer has to come off. My impact was powerful enough to take the bolt off. There is a flywheel lock that requires removal of the starter, but I didn't need it. The harmonic balancer puller is just your standard 'Zone issue free rental. Use a 1/2" drive socket as a spacer:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee215773ad400000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

To get the cam covers off, you should have pulled the connectors for the cam position sensors and phaser solenoids, but do it now if you haven't:

http://im1.shutterfly.com/media/47a1cf01b3127ccefefc5087f03d00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

You can pull the front cover with the phasers attached, as I did, but you probably ought to mark them and pull them anyway. Here is what the cover looks like:

http://im1.shutterfly.com/media/47a1cf11b3127ccefee94833d8df00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

There are 22 bolts that have to come out, and I was too lazy to look at each one and try to remember where it went. So I printed out the tightening diagram from the manual on two pages and taped them to a box:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee2d5693aaa00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Then, removing them in order, I punched them into the box as they came out (a knife helps punch the hole):

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3a838db2100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Be careful - the bolts have rubber insulators on them:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3ce2ddb0700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Once you get them all out, there is a jacking hole and pry points. Be patient when prying. And you will get more coolant out of the back of the water pump, where the cover mates to the block. You do not need to remove the water pump.

http://im1.shutterfly.com/media/47a1cc20b3127ccefe961ba8ec5100000010O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee2edc73a1800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3ba21db3100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee237fbbb7900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee222d3fbc300000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee2c110bbe900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Here is what the cover looks like off (not mine, but you get the picture):


12-01-2011, 11:56 PM
OK, here's the fun part - you need to turn the crank so that the cam timing marks are somewhere near the 12:00 position. That's right - no need to line up all the marks, they are only for installation. (And there's no way you could anyway, since they go out of position the minute you start the engine).

Here are the marks you are looking for - the EX for exhaust cam, IN for intake, with a triangle for the right side, a circle for the left:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3874e1ae800000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a0ce27b3127ccefb189fe528fe00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

The crank gear will have the dot around 9:00 pm and the slot for the pin / keyway at around 3:00 pm:

http://im1.shutterfly.com/media/47a1cc20b3127ccefe96b23b2d3e00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

Secure the cams with the special retaining tools (which are crazy pricey unless you find them on eBay), or have a buddy with two 20mm wrenches (yeah, right, you know you are going to hand him a couple of Crescents) hold the cams on the flats provided just forward of the forward cam lobes:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3e82cdb1500000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

This prevents the cams from popping from spring pressure when you remove the chains.

12-02-2011, 12:03 AM
Remove the tensioner bolts and tensioners, the tensioner shoe bolts and shoes, the guides, the chains, and the gears. The factory manual says the primary guide on the oil pump is not replaceable, but I got one from a dealer for around 10 bucks.

http://im1.shutterfly.com/media/47a1cc20b3127ccefe9794818ceb00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cc20b3127ccefe97ff40cc8700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cc20b3127ccefe964f276dc400000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-02-2011, 12:12 AM
I had never heard a noise like mine was making, and not being familiar with the engine otherwise, I suspected but was not certain that the noise was from the chain, especially before the cold start rattle started. Other candidates were bearing noise from the water pump, tensioners or the fan bracket assembly. As I disassembled the engine, I checked all of these, and they were smooth and quiet. So what about the chain components?

Well, there's your problem:

http://im1.shutterfly.com/media/47a1cf06b3127ccefee329529b9300000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee251bebb0f00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee37b619b8900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee386945aaa00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee38816db1f00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee2dce17abe00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

And the timing chain was "stretched" and worn on the outside (new chain on left for comparison):

http://im1.shutterfly.com/media/47a1cf06b3127ccefee2e10f3ad600000040O38IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D3/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf06b3127ccefee3b2665a4200000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-02-2011, 12:18 AM
Now time to clean up this mess:

http://im1.shutterfly.com/media/47a1cf08b3127ccefeeeae266d6a00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf08b3127ccefeeee2006d6a00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf08b3127ccefeef4dac8c7500000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf08b3127ccefeefbfe78c4700000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf08b3127ccefeefd15e8cc900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

12-02-2011, 12:20 AM
Finished product:

http://im1.shutterfly.com/media/47a1cf11b3127ccefee8d36cb81900000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf11b3127ccefee97e16d8e100000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf11b3127ccefee92fd4989300000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

http://im1.shutterfly.com/media/47a1cf11b3127ccefee97cbdd84b00000030O08IZtXLZszag9 vPhI/cC/f%3D0/ps%3D50/r%3D0/rx%3D550/ry%3D400/

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