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    Alero, Grand Am 1999-2005

    Timing Chain Cover, Chain, Sprockets, & Seal

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    Removal & Installation



    2.2L Engine
    1. Before servicing the vehicle, refer to the precautions section.
      2.  
    2. Remove the valve cover.
      3.  
    3. Remove the engine front cover as follows:
      1. Remove the front wheel.
        2.  
      2. Remove the engine splash shield.
        3.  
      3. Remove the drive belt.
        4.  
      4. Use crankshaft holding tool J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt.

        Click image to see an enlarged view

        Fig. Use crankshaft holding tool J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt-2.2L engine

        5.  
      5. Remove the crankshaft balancer bolt and discard. Remove the balancer.
        6.  
      6. Remove the drive belt tensioner.
        7.  
      7. Remove the water pump-to-front cover bolt.

        Click image to see an enlarged view

        Fig. Remove the water pump-to-front cover bolt-2.2L engine



        Click image to see an enlarged view

        Fig. Remove the front cover bolts and cover-2.2L engine

        8.  
      8. Remaining front cover-to-engine bolts, the cover and gasket.
        9.  

      4.  
    4. Rotate the engine until the crankshaft sprocket mark aligns with the second silver link (2) at the 5 o'clock position. Refer to the illustration.

      Click image to see an enlarged view

      Fig. Rotate the engine until the crankshaft sprocket mark aligns with the second silver link (2) at the 5 o'clock position-2.2L engine

      5.  
    5. Make sure the INT diamond on the intake camshaft sprocket is aligned with the copper link at (1) at the 2 o'clock position. Refer to the illustration.

      Click image to see an enlarged view

      Fig. Make sure the INT diamond on the intake camshaft sprocket is aligned with the copper link at (1) at the 2 o'clock position-2.2L engine

      6.  
    6. Make sure the EXH triangle on the exhaust camshaft sprocket is aligned with the silver link (3). Refer to the illustration.

      Click image to see an enlarged view

      Fig. Make sure the EXH triangle on the exhaust camshaft sprocket is aligned with the silver link (3)-2.2L engine

      7.  
    7. Remove or disconnect the following:

      Timing chain tensioner
       
      Timing chain tensioner guide
       
      Fixed timing chain guide access plug
       
      Fixed timing chain guide
       
      Upper timing chain guide
       

      8.  
    8. Use a 24 mm wrench to hold the camshafts from turning.

      Exhaust camshaft sprocket bolt and discard
       
      Exhaust camshaft sprocket
       
      Intake camshaft sprocket bolt and discard
       
      Intake camshaft sprocket
       
      Timing chain through the top of the cylinder head

      Click image to see an enlarged view

      Fig. Remove the intake camshaft sprocket, then the chain through the top of the head-2.2L engine

       
      Crankshaft sprocket
       
      Balance shaft drive chain tensioner
       
      Adjustable balance shaft chain guide
       
      Small balance shaft drive chain guide
       
      Upper balance shaft drive chain guide
       
      Balance shaft drive chain.

      Click image to see an enlarged view

      Fig. Remove the upper balance shaft chain guide, then the chain-2.2L engine

       

      9.  

    To install:

    1. Install or connect the following:

      Upper balance shaft chain guide and tighten to 89 inch lbs. (10 Nm)
       
      Small balance shaft chain guide and bolts and tighten to 89 inch lbs. (10 Nm)
       
      Adjustable balance shaft drive chain guide and bolts and tighten to 89 inch lbs. (10 Nm)
       

      2.  
    2. Turn the tensioner plunger 90 degrees in its bore and compress the plunger until a paper clip can be inserted through the hole in the plunger body and into hole in the tensioner plunger.

      Timing chain tensioner and bolts and tighten to 89 inch lbs. (10 Nm)
       

      3.  
    3. Remove the paper clip from the balance shaft drive chain tensioner.
      4.  
    4. Install the crankshaft sprocket with timing mark at the 5 o'clock position.

      Click image to see an enlarged view

      Fig. Install the crankshaft sprocket with timing mark at the 5 o'clock position-2.2L engine

      5.  
    5. 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.

      Click image to see an enlarged view

      Fig. 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 (1 & 2)-2.2L engine

      6.  
    6. Install or connect the following:

      Intake camshaft sprocket with the INT diamond at the 2 o'clock position

      Click image to see an enlarged view

      Fig. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position-2.2L engine

       

      7.  
    7. Hand tighten a NEW intake camshaft sprocket bolt.
      8.  
    8. Route the timing chain around the crankshaft sprocket with the second silver link aligning with the timing mark.
      9.  
    9. Route the timing chain around the intake camshaft sprocket with the copper colored link aligning with the INT diamond.

      Timing chain tensioner guide through the opening in the top of the cylinder head and tighten the bolts to 89 inch lbs. (10 Nm).
       
      Exhaust camshaft sprocket with the timing chain silver link at EXH triangle aligned at the 10 o'clock position.

      Click image to see an enlarged view

      Fig. Install the exhaust camshaft sprocket with the timing chain silver link at EXH triangle aligned at the 10 o'clock position-2.2L engine

       

      10.  
    10. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.
      11.  
    11. Hand tighten the NEW exhaust camshaft sprocket bolt.
      12.  
    12. Install the fixed timing chain guide and tighten the bolts to 89 inch lbs. (10 Nm).
      13.  
    13. Apply sealant, GM P/N 12345382 compound to thread and install the timing chain guide bolt access hole plug. Tighten the access hole plug to 30 ft. lbs. (40 Nm).

      Timing chain upper guide and bolts and tighten to 89 inch lbs. (10 Nm)
       

      14.  
    14. Measure the timing chain tensioner. In a fully compressed, non-active state, the tensioner will measure 2.83 in (72mm). A tensioner in the active state will measure 3.35 in (85mm). To put the tensioner in a non-active state, hold the flat end of the tensioner with a wrench and rotate the piston clockwise for slightly less than one full turn.

      Timing chain tensioner and tighten the tensioner to 55 ft. lbs. (75 Nm)
       

      15.  
    15. 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.
      16.  
    16. Use a 24 mm wrench to hold the camshaft and tighten the new bolts to 63 ft. lbs. (85 Nm) plus an additional 30 degrees.
      17.  
    17. Install the valve cover.
      18.  
    18. Install the engine front cover as follows:
      1. Install front cover gasket, cover and cover-to-engine bolts.
        2.  
      2. Install the water pump-to-front cover bolts. Tighten all the cover bolts to 15 ft. lbs. (20 Nm).
        3.  
      3. Install the drive belt tensioner and tighten the bolt to 33 ft. lbs. (45 Nm).
        4.  
      4. Install the crankshaft balancer and bolt.
        5.  
      5. Use crankshaft holding tool J 38122-A to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. Tighten the bolt to 74 ft. lbs. (100 Nm) plus an additional 75 degrees.
        6.  
      6. Install the engine splash shield.
        7.  
      7. Install the drive belt.
        8.  
      8. Install the front wheel.
        9.  

      19.  
    19. Connect negative battery cable.
      20.  

    2.4L Engine

    NOTE
    It is recommended that the entire procedure be reviewed before attempting to service the timing chain.

    1. Before servicing the vehicle, refer to the precautions section.
      2.  
    2. Drain the cooling system.
      3.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Coolant surge tank
       
      Accessory drive belt
       
      Alternator
       

      4.  
    4. Install an engine support.
      5.  
    5. Remove or disconnect the following:

      Upper cover fasteners
       
      Front cover vent hose
       
      Right engine mount and bracket
       
      Right front wheel
       
      Right lower splash shield
       
      Crankshaft balancer
       
      Lower cover fasteners
       
      Front cover
       

      6.  
    6. Rotate the crankshaft clockwise, as viewed from front of engine (normal rotation) until the camshaft sprocket's timing dowel pin holes align with the timing chain housing holes. The crankshaft sprocket mark should align with the engine mark. The crankshaft sprocket keyway should point upward and align with the cylinder bores centerline. This is the normal timed position.
      7.  
    7. Remove the timing chain guides.
      8.  
    8. Remove the timing chain tensioner.
      NOTE
      Be sure all the slack in the timing chain is above the tensioner assembly when removing it.


      CAUTION
      The tensioner plunger is spring loaded and could fly out causing personal injury.

      9.  
    9. Remove or disconnect the following:

      Timing chain
       
      Camshaft sprockets
       

      10.  

    To install:

    1. Install or connect the following:

      Camshaft sprockets. Torque the bolts to 52 ft. lbs. (70 Nm).
       
      Camshaft sprocket alignment pin through the camshaft sprockets holes into the timing chain housing holes to position the camshafts for timing.
       

      2.  
    2. If the camshafts are out of position and must be rotated more than 1 / 8 turn in order to install the alignment dowel pins, perform the following:
      1. Rotated the crankshaft 90 degrees clockwise off Top Dead Center (TDC) in order to give the valves adequate clearance to open.
        2.  
      2. Once the camshafts are positioned and the dowels installed, rotate the crankshaft counterclockwise back to TDC.
        WARNING
        Do not rotate the crankshaft clockwise to TDC or valve and piston damage may occur.

        3.  

      3.  
    3. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket.

      Click image to see an enlarged view

      Fig. Timing chain and sprocket alignment positions-2.4L DOHC engine

      4.  
    4. Remove the alignment dowel pin from the intake camshaft. Using a dowel pin remover tool, rotate the intake camshaft sprocket counterclockwise enough to slide the timing chain over the intake camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the 2 camshaft sprockets will tighten.
      NOTE
      If properly timed, the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated.

      5.  
    5. Leave the alignment dowel pins installed.
      6.  
    6. With slack removed from chain between intake camshaft sprocket and crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain 1 tooth forward or rearward, remove slack and recheck the marks.
      7.  
    7. Tighten the chain housing to engine stud. The stud is installed under the timing chain. Torque it to 19 ft. lbs. (26 Nm).
      8.  
    8. Reload the timing chain tensioner as follows:
      1. Form a keeper from heavy gauge wire.
        2.  
      2. Slightly, compress the shoe plunger and insert a small screwdriver into the access hole.
        3.  
      3. Release the ratchet pawl and compress the plunger completely into the hole.
        4.  
      4. Insert the keeper between the access hole and the blade.
        5.  

      9.  
    9. Install or connect the following:
      NOTE
      Recheck plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.



      Tensioner assembly to the chain housing. Torque the bolts to 89 inch lbs. (10 Nm).
       



      Tensioner shoe and retainer. Torque the bolts to 89 inch lbs. (10 Nm).
       

      10.  
    10. Remove the alignment dowel pins. Rotate crankshaft clockwise 2 full rotations. Align the crankshaft timing mark with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly.
      WARNING
      If the engine is not correctly timed, severe engine damage could occur.

      11.  
    11. Install or connect the following:

      Timing chain guides
       
      New seal into the front cover by lubricating the seal lip and tapping it into place
       
      Front cover and gaskets. Torque the nuts and bolts to 106 inch lbs. (12 Nm).
       
      Crankshaft balancer. Torque the bolt to 129 ft. lbs. (175 Nm).
       
      Right front lower splash shield
       
      Front wheel. Torque the nuts to 100 ft. lbs. (140 Nm).
       
      Right engine mount bracket. Torque the bolts to 81 ft. lbs. (110 Nm) plus an additional 90 degree turn.
       
      Right engine mount. Torque the bolt to 49 ft. lbs. (60 Nm).
       
      Upper cover vent hose
       

      12.  
    12. Remove the engine support.
      13.  
    13. Install or connect the following:

      Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
       
      Accessory drive belt
       
      Coolant surge tank
       
      Negative battery cable
       

      14.  
    14. Refill the cooling system.
      15.  
    15. Start the engine and check for leaks.
      16.  

    3.1L & 3.4L Engines
    1. Before servicing the vehicle, refer to the precautions section.
      2.  
    2. Disconnect the negative battery cable.
      3.  
    3. Drain the cooling system.
      4.  
    4. Drain the engine oil.
      5.  
    5. Discharge and recover the A/C refrigerant.
      6.  
    6. Install an engine support fixture.
      7.  
    7. Remove or disconnect the following:

      Front engine mount and bracket
       
      Accessory drive belt
       
      Air cleaner assembly
       
      Air intake duct
       
      2 upper air conditioning compressor mounting bolts
       
      Power steering pump
       
      Alternator and bracket
       
      Right front wheel
       
      Right wheel well splash shield
       
      Crankshaft balancer
       
      Drive belt tensioner
       
      Right Wheel Speed Sensor (WSS) harness at the suspension support
       
      Lower ball joint
       
      Stabilizer bar from the control arm and suspension support
       
      Suspension support
       
      A/C compressor-to-oil pan bolts
       
      Oil filter and adapter
       
      Starter motor
       
      Oil pan
       
      Crankshaft Position (CKP) sensor
       
      Lower front cover bolts
       
      Coolant bypass hose
       
      Upper radiator hose
       
      Engine front cover
       

      8.  
    8. Place the number one piston at Top Dead Center (TDC).
      9.  
    9. Remove or disconnect the following:

      Camshaft sprocket
       
      Timing chain
       
      Crankshaft sprocket

      Click image to see an enlarged view

      Fig. Be sure to align the damper mark (1) with the crankshaft mark (2) and the damper mark (3) with the camshaft sprocket mark (4)-3.1L & 3.4L engines

       

      10.  

    To install:

    1. Install the crankshaft sprocket.
      NOTE
      Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.

      2.  
    2. Place the timing chain over the camshaft sprocket and hold the sprocket so the timing mark is pointing down and the timing chain is hanging off the sprocket.
      3.  
    3. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft.
      4.  
    4. Verify that the marks are aligned; the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position.
      NOTE
      The No. 1 piston will be at TDC and the No. 4 piston will also be at TDC but on the compression stroke.

      5.  
    5. Torque the camshaft sprocket bolt to 103 ft. lbs. (140 Nm).
      6.  
    6. Install or connect the following:

      Front cover, using a new gasket and seal. Torque the small bolts to 15 ft. lbs. (21 Nm) and the long bolts to 35 ft. lbs. (47 Nm).
       
      Upper radiator hose
       
      Coolant bypass hose
       
      CKP sensor
       
      Oil pan. Torque the bolts to 18 ft. lbs. (25 Nm).
       
      Starter motor. Torque the bolts to 32 ft. lbs. (43 Nm).
       
      Oil filter adapter and filter
       
      A/C compressor-to-oil pan bolts. Torque the bolts to 37 ft. lbs. (50 Nm).
       
      Suspension support. Torque the bolts to 61 ft. lbs. (82 Nm).
       
      Stabilizer bar. Torque the bolts to 13 ft. lbs. (17 Nm).
       
      Ball joint. Torque the nuts to 41 ft. lbs. (55 Nm).
       
      WSS electrical connector
       
      Drive belt tensioner. Torque the bolts to 33 ft. lbs. (45 Nm).
       
      Crankshaft balancer. Torque the bolt to 76 ft. lbs. (103 Nm).
       
      Right wheel well splash shield
       
      Right front wheel
       
      Alternator. Torque the front bolt to 37 ft. lbs. (50 Nm) and the rear bolt to 18 ft. lbs. (25 Nm).
       
      2 upper air conditioning compressor mounting bolts. Torque the bolts to 37 ft. lbs. (50 Nm).
       
      Power steering pump. Torque the bolts to 25 ft. lbs. (34 Nm).
       
      Air intake duct
       
      Air cleaner assembly
       
      Accessory drive belt
       
      Front engine mount and bracket. Torque the 8mm bolts to 15 ft. lbs. (20 Nm) and the 12mm bolts to 30 ft. lbs. (40 Nm).
       
      Negative battery cable
       

      7.  
    7. Evacuate and recharge the A/C system.
      8.  
    8. Refill the engine oil and coolant.
      9.  
    9. Start the engine and check for leaks.
      10.  

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