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.  
  3. Remove the valve cover.
  4.  
  5. Remove the engine front cover as follows:
    1. Remove the front wheel.
    2.  
    3. Remove the engine splash shield.
    4.  
    5. Remove the drive belt.
    6.  
    7. 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

    8.  
    9. Remove the crankshaft balancer bolt and discard. Remove the balancer.
    10.  
    11. Remove the drive belt tensioner.
    12.  
    13. 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

    14.  
    15. Remaining front cover-to-engine bolts, the cover and gasket.
    16.  

  6.  
  7. 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

  8.  
  9. 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

  10.  
  11. 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

  12.  
  13. 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
     

  14.  
  15. 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

     

  16.  

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.  
  3. 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)
     

  4.  
  5. Remove the paper clip from the balance shaft drive chain tensioner.
  6.  
  7. 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

  8.  
  9. 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

  10.  
  11. 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

     

  12.  
  13. Hand tighten a NEW intake camshaft sprocket bolt.
  14.  
  15. Route the timing chain around the crankshaft sprocket with the second silver link aligning with the timing mark.
  16.  
  17. 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

     

  18.  
  19. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.
  20.  
  21. Hand tighten the NEW exhaust camshaft sprocket bolt.
  22.  
  23. Install the fixed timing chain guide and tighten the bolts to 89 inch lbs. (10 Nm).
  24.  
  25. 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)
     

  26.  
  27. 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)
     

  28.  
  29. 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.
  30.  
  31. 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.
  32.  
  33. Install the valve cover.
  34.  
  35. Install the engine front cover as follows:
    1. Install front cover gasket, cover and cover-to-engine bolts.
    2.  
    3. Install the water pump-to-front cover bolts. Tighten all the cover bolts to 15 ft. lbs. (20 Nm).
    4.  
    5. Install the drive belt tensioner and tighten the bolt to 33 ft. lbs. (45 Nm).
    6.  
    7. Install the crankshaft balancer and bolt.
    8.  
    9. 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.
    10.  
    11. Install the engine splash shield.
    12.  
    13. Install the drive belt.
    14.  
    15. Install the front wheel.
    16.  

  36.  
  37. Connect negative battery cable.
  38.  

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.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Coolant surge tank
     
    Accessory drive belt
     
    Alternator
     

  6.  
  7. Install an engine support.
  8.  
  9. 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
     

  10.  
  11. 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.
  12.  
  13. Remove the timing chain guides.
  14.  
  15. 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.

  16.  
  17. Remove or disconnect the following:

    Timing chain
     
    Camshaft sprockets
     

  18.  

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.  
  3. 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.  
    3. 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.

    4.  

  4.  
  5. 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

  6.  
  7. 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.

  8.  
  9. Leave the alignment dowel pins installed.
  10.  
  11. 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.
  12.  
  13. Tighten the chain housing to engine stud. The stud is installed under the timing chain. Torque it to 19 ft. lbs. (26 Nm).
  14.  
  15. Reload the timing chain tensioner as follows:
    1. Form a keeper from heavy gauge wire.
    2.  
    3. Slightly, compress the shoe plunger and insert a small screwdriver into the access hole.
    4.  
    5. Release the ratchet pawl and compress the plunger completely into the hole.
    6.  
    7. Insert the keeper between the access hole and the blade.
    8.  

  16.  
  17. 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).
     

  18.  
  19. 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.

  20.  
  21. 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
     

  22.  
  23. Remove the engine support.
  24.  
  25. Install or connect the following:

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

  26.  
  27. Refill the cooling system.
  28.  
  29. Start the engine and check for leaks.
  30.  

3.1L & 3.4L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Discharge and recover the A/C refrigerant.
  10.  
  11. Install an engine support fixture.
  12.  
  13. 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
     

  14.  
  15. Place the number one piston at Top Dead Center (TDC).
  16.  
  17. 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

     

  18.  

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.  
  3. 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.
  4.  
  5. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft.
  6.  
  7. 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.

  8.  
  9. Torque the camshaft sprocket bolt to 103 ft. lbs. (140 Nm).
  10.  
  11. 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
     

  12.  
  13. Evacuate and recharge the A/C system.
  14.  
  15. Refill the engine oil and coolant.
  16.  
  17. Start the engine and check for leaks.
  18.  

 
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