Alero, Grand Am 1999-2005

Camshaft, Bearings & Lifters

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Bearing Replacement



  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine assembly from the vehicle, then remove the camshaft from the engine.
  4.  
  5. Detach the camshaft rear plug.
  6.  
  7. Assemble a suitable bearing removal tool (depending upon engine application), according to the manufacturer's directions.
  8.  
  9. Remove the camshaft bearings.
    NOTE
    Never reuse camshaft bearings once they have been removed. Always install new bearings.



    Click image to see an enlarged view

    Fig. Using the proper tool to removal and/or install camshaft bearings-3.1L engine shown

  10.  

To install:

  1. Select and install new front, rear and intermediate camshaft bearings:
    1. Assembly a suitable bearing installation tool, following the manufacturer's instructions.
    2.  
    3. Place the bearing on the tool.
    4.  
    5. Index the bearing oil holes with cylinder block oil passages.
    6.  

  2.  
  3. Apply sealer 1052914 or RTV equivalent to the camshaft plug, then install the plug.
  4.  
  5. Install the camshaft into the engine, then install the engine in the vehicle.
  6.  
  7. Connect the negative battery cable.
  8.  

Inspection



Using a suitable solvent, degrease the camshaft and clean out all of the oil holes. Visually inspect the cam lobes and bearing journals for excessive wear, galling, gouges or overheating which may be indicated by discoloration. If a lobe is questionable, check all of the lobes. If a journal or lobe is worn, the camshaft MUST BE reground or replaced. Also, inspect the sprocket, keyway and threads.


NOTE
If a journal is worn, there is a good chance that the bearings are worn and need replacement.

If the camshaft is damaged, DO NOT attempt to repair it, it must be replaced. If a new camshaft is installed, all of the valve lifters must be replaced.

Measure cam lift using the following instructions:

  1. Lubricate the camshaft bearings with a suitable camshaft and lifter prelube.
  2.  
  3. Carefully insert the camshaft. If the cam bearings are badly worn or damaged, set the camshaft on -V'' blocks instead.
  4.  
  5. Install a suitable measure tool, depending upon engine application, and measure the cam lift. Compare to the specifications in the chart in this section. If any cam lift is out of specification, replace the camshaft.
  6.  

Measure the run-out and diameter of the bearing journals using a micrometer. If out of specification, replace the camshaft.

Removal & Installation



2.4L Engine
Exhaust Camshaft

NOTE
Anytime the camshaft housing-to-cylinder head bolts are loosened or removed, the camshaft housing-to-cylinder head gasket must be replaced.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Use a spark plug boot wire remover to remove connector assemblies.


    NOTE
    Leave 2 bolts loosely in place to hold the camshaft housing while separating the camshaft cover from housing.



    Negative battery cable
     
    Ignition assembly electrical connector
     
    4 ignition assembly-to-camshaft housing bolts and the assembly by pulling it straight up
     



    Oil pressure switch electrical connector
     
    Transaxle fill tube
     
    Timing chain and camshaft sprockets
     
    Timing chain housing bolts but do not remove from the engine
     
    Camshaft housing cover-to-camshaft housing bolts
     
    Camshaft housing-to-cylinder head bolts by reversing of the tightening sequence
     

  4.  
  5. Press the cover off the housing by threading 4 of the housing-to-cylinder head bolts into the tapped camshaft housing cover holes. Tighten the bolts in evenly so the cover does not bind on the dowel pins.
  6.  
  7. Remove the camshaft housing cover and discard the gaskets.
  8.  
  9. Note the position of the chain sprocket dowel pin for reassembly.
  10.  
  11. Remove or disconnect the following:
    NOTE
    The camshaft seal must be replaced any time the housing and cover are separated.


    NOTE
    Store the valve lifters in order so that they may be installed in the their locations.



    Camshaft
     
    Camshaft oil seal from camshaft and discard it
     



    Valve lifters from the camshaft housing
     
    Camshaft carrier from the cylinder head and discard the gasket
     

  12.  

To install:

  1. Clean all the gasket surfaces completely.
  2.  
  3. Install or connect the following:
    NOTE
    Install 1 bolt loosely to hold the housing in place.


    NOTE
    If the camshaft was replaced the valve lifters must also be replaced.



    New camshaft housing gasket
     
    Camshaft housing
     

  4.  
  5. Install the lifters into their original bores.
  6.  
  7. Lubricate the camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.
  8.  
  9. Install or connect the following:
    NOTE
    The seals for the intake and exhaust covers are different and the correct seals must be used.



    Camshaft in it original position with the timing chain sprocket dowel pin straight up and aligned with the centerline of the lifter bores.
     
    New Orange camshaft housing cover seal
     

  10.  
  11. Remove the bolt holding the housing in place.
  12.  
  13. Apply thread locking compound to the camshaft housing and cover bolt threads.
  14.  
  15. Install or connect the following:

    Camshaft housing cover. Tighten the bolts, in sequence, to 11 ft. lbs. (15 Nm) plus an additional 90 degree turn (long bolts) and 11 ft. lbs. (15 Nm) plus an additional 30 degree turn (short bolts).
     
    Timing chain housing mounting bolts
     
    Timing chain and sprockets
     
    New fuel injector O-ring seals lubricated with engine oil
     
    Fuel rail. Tighten the bolts to 19 ft. lbs. (26 Nm).
     
    Transaxle fill tube
     
    Oil pressure switch electrical connector
     
    Ignition assembly on the camshaft housing. Tighten the bolts to 11 ft. lbs. (15 Nm), plus an additional 30 degree turn.
     
    Ignition assembly electrical connector
     
    Negative battery cable
     

  16.  
  17. Start the vehicle and verify proper operation and no leaks.
  18.  

Intake Camshaft

NOTE
Anytime the camshaft housing-to-cylinder head bolts are loosened or removed, the camshaft housing-to-cylinder head gasket must be replaced.

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Use a spark plug boot wire remover to remove connector assemblies.


    NOTE
    Leave 2 bolts loosely in place to hold the camshaft housing while separating the camshaft cover from housing.



    Negative battery cable
     
    Ignition assembly electrical connector
     
    4 ignition assembly-to-camshaft housing bolts and the assembly by pulling it straight up
     



    Camshaft Position (CMP) sensor electrical connector
     
    Power steering pump and move it aside without disconnecting the lines
     
    Vacuum line from fuel pressure regulator
     
    Fuel injector wiring harness
     
    Both fuel line-to-intake camshaft housing clamps
     
    Fuel rail-to-camshaft housing bolts
     
    Fuel rail from the cylinder head and move it aside with the fuel lines attached
     
    Timing chain and camshaft sprockets
     
    Timing chain housing bolts but do not remove from the engine
     
    Camshaft housing cover-to-camshaft housing bolts
     
    Camshaft housing-to-cylinder head bolts by reversing of the tightening sequence
     

  4.  
  5. Press the cover off the housing by threading 4 of the housing-to-cylinder head bolts into the tapped camshaft housing cover holes. Tighten the bolts in evenly so the cover does not bind on the dowel pins.
  6.  
  7. Remove the camshaft housing cover and discard the gaskets.
  8.  
  9. Note the position of the chain sprocket dowel pin for reassembly.
  10.  
  11. Remove or disconnect the following:
    NOTE
    The camshaft seal must be replaced any time the housing and cover are separated.


    NOTE
    Store the valve lifters in order so that they may be installed in the their locations.



    Camshaft
     
    Camshaft oil seal from camshaft and discard it
     



    Valve lifters from the camshaft housing
     
    Camshaft carrier from the cylinder head and discard the gasket
     

  12.  

To install:

  1. Clean all the gasket surfaces completely.
  2.  
  3. Install or connect the following:
    NOTE
    Install 1 bolt loosely to hold the housing in place.


    NOTE
    If the camshaft was replaced the valve lifters must also be replaced.



    New camshaft housing gasket
     
    Camshaft housing
     

  4.  
  5. Install the lifters into their original bores.
  6.  
  7. Lubricate the camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.
  8.  
  9. Install or connect the following:
    NOTE
    The seals for the intake and exhaust covers are different and the correct seals must be used.



    Camshaft in its original position with the timing chain sprocket dowel pin straight up and aligned with the centerline of the lifter bores.
     
    New Green camshaft housing cover seal
     

  10.  
  11. Remove the bolt holding the housing in place.
  12.  
  13. Apply thread locking compound to the camshaft housing and cover bolt threads.
  14.  
  15. Install or connect the following:

    Camshaft housing cover. Tighten the bolts, in sequence, to 11 ft. lbs. (15 Nm) plus an additional 90 degree turn (long bolts) and 11 ft. lbs. (15 Nm) plus an additional 30 degree turn (short bolts).
     
    Timing chain housing bolts
     
    Timing chain and sprockets
     
    New fuel injector O-ring seals lubricated with engine oil
     
    Fuel rail. Tighten the bolts to 19 ft. lbs. (26 Nm).
     
    Ignition assembly on the camshaft housing. Tighten the bolts to 11 ft. lbs. (15 Nm), plus an additional 30 degree turn.
     
    Ignition assembly electrical connector
     
    Negative battery cable
     

  16.  
  17. Start the vehicle and verify proper operation and no leaks.

    Click image to see an enlarged view

    Fig. Camshaft housing bolt tightening sequence-2.4L engine

  18.  

3.1L & 3.4L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    WARNING
    When removing valvetrain components they must be marked for installation in their original location.


    WARNING
    Avoid damaging the camshaft bearing surfaces.



    Engine assembly
     



    Rocker arm covers
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Lifter guides
     
    Valve lifter(s) from the bores
     
    Crankshaft balancer and front cover
     
    Timing chain and sprockets
     
    Oil pump driven gear
     
    Camshaft thrust plate
     
    Camshaft
     

  6.  

To install:

  1. Coat the camshaft with camshaft lubricant.
  2.  
  3. Install or connect the following:

    Camshaft
     
    Camshaft thrust plate. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Oil pump driven gear. Torque the bolt to 27 ft. lbs. (36 Nm).
     
    Timing chain and sprocket. Torque the sprocket bolt to 103 ft. lbs. (140 Nm).
     
    Front cover. Torque the bolts to 15 ft. lbs. (21 Nm).
     
    Crankshaft balancer. Torque the bolt to 76 ft. lbs. (103 Nm).
     

  4.  
  5. Lubricate the bearing surfaces with Molykote®.
  6.  
  7. Install or connect the following:

    Lifters in their original locations
     
    Lifter guides. Torque the guide bolts to 89 inch lbs. (10 Nm).
     
    Pushrods and rocker arms. Torque the nuts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn.
     
    Intake manifold
     
    Rocker arm covers. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Engine assembly
     
    Negative battery cable
     

  8.  
  9. Adjust the valves, as required. Start the engine and verify no oil leaks.
  10.  

 
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