Aurora 2001-2003

Camshaft, Bearings & Lifters

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Removal & Installation




NOTE
All valve train components should be kept in the order that they were removed, so that they can be reinstalled in their original position.

3.5L Engine
Left Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove or disconnect the following:

    Fuel injector sight shield
     
    Oil level indicator tube
     
    Positive Crankcase Ventilation (PCV) valve
     
    Spark plug wires
     
    Ignition coil assembly
     
    Fuel injector wiring harness
     
    Engine wiring harness
     
    Camshaft cover
     

  6.  
  7. Install the camshaft holding fixture (J 42038) on the camshafts.
  8.  
  9. Remove or disconnect the following:

    Camshaft sprockets with the secondary drive chains
     
    Camshaft bearing caps
     
    Camshaft holding fixture
     
    Camshafts
     
    Rocker arms
     
    Lifters

    Click image to see an enlarged view

    Fig. Camshaft holding fixture J-42038 installed on the camshafts-3.5L engine



    Click image to see an enlarged view

    Fig. Camshaft identification-3.5L engine



    Click image to see an enlarged view

    Fig. Use the flats on the camshaft if rotation is necessary for installation of the holding tool-3.5L engine



    Click image to see an enlarged view

    Fig. Before installation, compress the tensioner and lock it in place with a piece of wire-3.5L engine

     

  10.  

To install:

  1. Coat the lifters with clean engine oil and place them into position in the engine.
  2.  
  3. Coat the rocker arms with clean engine oil and set them in place in the head.
  4.  
  5. Coat the camshafts with clean engine oil and place them in their proper position in the head.
  6.  
  7. Install or connect the following:

    Camshaft holding fixture
     
    Camshaft bearing caps. Torque the bolts to 71 inch lbs. (8 Nm) plus an additional 22 degree turn.
     
    Camshaft sprockets with the secondary drive chains. Torque the bolts to 18 ft. lbs. (25 Nm) plus an additional 45 degree turn.
     

  8.  
  9. Remove the camshaft holding fixture from the head.
  10.  
  11. Install or connect the following:

    Camshaft cover (seals are reusable if they are not damaged). Torque the bolts to 80 inch lbs. (9 Nm).
     
    Engine wiring harness
     
    Fuel injector wiring harness
     
    Ignition coil assembly
     
    Spark plug wires
     
    PCV valve and feed tube
     
    Oil level indicator tube
     
    Fuel injector sight shield. Torque the nuts to 27 inch lbs. (3 Nm).
     
    Negative battery cable
     

  12.  

Right Side (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Transmission filler tube
     
    Fuel injector sight shield
     
    Positive Crankcase Ventilation (PCV) feed tube
     
    Engine wiring harness clips
     
    Oxygen Sensor (O 2 S) electrical connector
     
    Spark plug wires
     
    Ignition coil assembly
     
    Camshaft cover
     

  4.  
  5. Install the camshaft holding fixture (tool J-42038).
  6.  
  7. Remove or disconnect the following:

    Camshaft position sensor
     
    Camshaft sprockets with the secondary drive chains
     
    Camshaft bearing caps
     
    Camshaft holding fixture
     
    Camshafts
     
    Rocker arms
     
    Lifters
     

  8.  

To install:

  1. Coat the lifters with clean engine oil and place them into position in the engine.
  2.  
  3. Coat the rocker arms with clean engine oil and set them in place in the head.
  4.  
  5. Coat the camshafts with clean engine oil and place them in position in the head.
  6.  
  7. Install or connect the following:

    Camshaft holding fixture
     
    Camshaft bearing caps. Torque the bolts to 71 inch lbs. (8 Nm). plus an additional 22 degree turn.
     
    Camshaft sprockets with secondary drive chains. Torque the bolts to 18 ft. lbs. (25 Nm) plus an additional 45 degree turn.
     
    Camshaft position sensor
     

  8.  
  9. Remove the camshaft holding fixture.
  10.  
  11. Install or connect the following:

    Camshaft cover (seals are reusable if undamaged). Torque the bolts to 80 inch lbs. (9 Nm).
     
    Ignition coil assembly
     
    Spark plug wires
     
    O 2 S electrical connector
     
    Engine wiring harness clips
     
    PCV feed tube
     
    Fuel injector sight shield. Torque the nuts to 27 inch lbs. (3 Nm).
     
    Transmission filler tube
     
    Negative battery cable
     

  12.  

4.0L Engine
Left Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:
    NOTE
    DO NOT reuse the camshaft seal.



    Negative battery cable
     
    Fuel injector sight shield
     
    Inlet radiator hose from the water housing crossover
     
    Positive Crankcase Ventilation (PCV) fresh air tube from the left side camshaft cover
     
    Ignition coil cassette and spark plug boots
     
    2 pushnuts securing the engine coolant heater wire, if equipped and position aside
     
    Surge tank pipe from the fuel rail studs and carefully position aside
     
    Cable harness clips at the front of the camshaft cover and position the cable harness aside
     
    AIR valve bracket nut closest to the center of the engine. Pry outward slightly on the AIR valve bracket in order to gain clearance to remove the water pump drive belt shield nut.
     
    Water pump drive belt shield and belt
     
    Water pump belt tensioner
     
    3 camshaft seal retainer bolts
     



    Camshaft seal
     
    Camshaft cover
     

  6.  
  7. Rotate the crankshaft to Top Dead Center (TDC) of the number 1 cylinders compression stroke, both camshaft sprocket drive pins should be at the top of their rotation.
  8.  
  9. Install the camshaft holding tool J44212 over the camshafts.

    Click image to see an enlarged view

    Fig. Rotate the crankshaft to Top Dead Center (TDC) of the number 1 cylinders compression stroke, both camshaft sprocket drive pins should be at the top of their rotation



    Click image to see an enlarged view

    Fig. Install the camshaft holding tool J44212 over the camshafts



    Click image to see an enlarged view

    Fig. Install Secondary Drive Timing Chain/Sprocket Holding Fixture Tool J 44213 onto the front rail of the cylinder head



    Camshaft sprocket bolts
     

  10.  
  11. Install the Secondary Drive Timing Chain/Sprocket Holding Fixture Tool J 44213 onto the front rail of the cylinder head.
  12.  
  13. Remove the secondary camshaft drive chain guide upper bolt access plug.
  14.  
  15. Loosen the secondary camshaft drive chain guide upper bolt ONLY two turns.
  16.  
  17. Slide the intake and exhaust camshaft sprockets onto the pins of the Secondary Drive Timing chain/Sprocket Holding Fixture Tool J 44213.
  18.  
  19. Alternately loosen the camshaft bearing cap bolts a few turns at a time until all valve spring pressure has been released.
  20.  
  21. Remove the camshaft bearing caps.
  22.  
  23. Remove the camshaft holding tool from the camshafts.
  24.  
  25. Remove the camshafts and followers.
  26.  

To install:

  1. Lubricate the camshaft lobes with assembly lubricant, and the camshaft journals with engine oil.
  2.  
  3. Install or connect the following:
    NOTE
    The camshafts can be identified by a stamping near the rear journal. For example: L-EXH is defined as Left bank Exhaust.



    Camshaft with the camshaft sprocket drive pins near the top of their rotation and the camshaft lobes in a neutral position.
     

  4.  
  5. Observe the markings on the camshaft bearing caps. Each camshaft bearing cap is marked in order to identify its location. The markings have the following meanings:
    1. The arrow should point to the front of the engine.
    2.  
    3. The number indicates the position from the front of the engine.
    4.  
    5. The "E" indicates the exhaust camshaft.
    6.  
    7. The "I" indicates the intake camshaft.
    8.  

  6.  
  7. Apply a liberal amount of lubricant GM P/N 12345001 or equivalent to the camshaft bearing caps.
  8.  
  9. Install the camshaft bearing caps and bolts. Tighten in sequence as follows:
    1. Alternately hand tighten the camshaft bearing cap bolts a few turns at a time until all caps are fully seated.
    2.  
    3. Tighten camshaft bearing cap bolts to 44 inch lbs. (5 Nm).
    4.  
    5. Tighten camshaft bearing cap bolts an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Left cylinder head camshaft bearing cap tightening sequence-4.0L (VIN C) engine

    6.  

  10.  
  11. Align the camshafts.
  12.  
  13. Install the camshaft holding fixture.
    NOTE
    Ensure the camshaft sprockets properly engage the camshaft sprocket drive pins and camshafts.

  14.  
  15. Slide the intake and exhaust camshaft sprockets off the pins of the Secondary Drive Timing chain/Sprocket Holding Fixture Tool J 44213 and onto the pins of the camshafts.
  16.  
  17. Tighten the secondary camshaft drive chain guide upper bolt to 18 ft. lbs. (25 Nm).
  18.  
  19. Install the secondary camshaft drive chain guide upper bolt access plug and tighten to 39 inch lbs. (4.5Nm).
  20.  
  21. Remove the Secondary Drive Timing chain/Sprocket Holding Fixture Tool J 44213 while carefully holding the camshaft sprockets against the camshafts.
  22.  
  23. Install the camshaft sprocket bolts and tighten to 89 ft. lbs. (120 Nm).
  24.  
  25. Verify the camshaft sprocket alignment.
  26.  
  27. Remove the camshaft holding tool.
  28.  
  29. Install or connect the following:

    Camshaft cover and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Camshaft seal lips lubricated with clean oil
     
    Camshaft seal retainers coated with sealer GM P/N 1052080 and tighten to 27 inch lbs. (3 Nm)
     
    Water pump belt tensioner
     
    Water pump drive belt and shield
     
    AIR valve bracket nut to 80 inch lbs. (9Nm)
     
    Cable harness clips at the front of the camshaft cover
     
    2 pushnuts securing the engine coolant heater wire, if equipped
     
    Inlet radiator hose to the water housing crossover
     
    Fuel injector sight shield
     
    Surge tank pipe to the fuel rail studs
     
    Ignition coil cassette and spark plug boots
     
    PCV fresh air tube to the left side camshaft cover
     
    Fuel injector sight shield
     
    Negative battery cable
     

  30.  
  31. Refill the cooling system.
  32.  

Right Side (Rear)
  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
     
    Fuel injector sight shield
     
    Positive Crankcase Ventilation (PCV) valve from the camshaft cover
     
    Vacuum tubes from the AIR vent solenoid
     
    AIR vent solenoid electrical connector
     
    AIR control valve bracket
     
    Nut securing the AIR tube
     
    Ignition coil cassette and spark plug boots
     
    Cable harness clips at the front of the camshaft cover and position the cable harness aside
     
    Camshaft cover
     

  6.  
  7. Rotate the crankshaft to Top Dead Center (TDC) of the number 1 cylinders compression stroke, both camshaft sprocket drive pins should be at the top of their rotation.
  8.  
  9. Install the camshaft holding tool J44212 over the camshafts.

    Camshaft sprocket bolts
     

  10.  
  11. Install the Secondary Drive Timing Chain/Sprocket Holding Fixture Tool J 44213 onto the front rail of the cylinder head.
  12.  
  13. Remove the secondary camshaft drive chain guide upper bolt access plug.
  14.  
  15. Loosen the secondary camshaft drive chain guide upper bolt ONLY two turns.
  16.  
  17. Slide the intake and exhaust camshaft sprockets onto the pins of the Secondary Drive Timing chain/Sprocket Holding Fixture Tool J 44213.
  18.  
  19. Alternately loosen the camshaft bearing cap bolts a few turns at a time until all valve spring pressure has been released.
  20.  
  21. Remove the camshaft bearing caps.
  22.  
  23. Remove the camshaft holding tool from the camshafts.
  24.  
  25. Remove the camshafts and followers.
  26.  

To install:

  1. Lubricate the camshaft lobes with assembly lubricant, and the camshaft journals with engine oil.
  2.  
  3. Install or connect the following:
    NOTE
    The camshafts can be identified by a stamping near the rear journal. For example: L-EXH is defined as Left bank Exhaust.



    Camshaft with the camshaft sprocket drive pins near the top of their rotation and the camshaft lobes in a neutral position.
     

  4.  
  5. Observe the markings on the camshaft bearing caps. Each camshaft bearing cap is marked in order to identify its location. The markings have the following meanings:
    1. The arrow should point to the front of the engine.
    2.  
    3. The number indicates the position from the front of the engine.
    4.  
    5. The "E" indicates the exhaust camshaft.
    6.  
    7. The "I" indicates the intake camshaft.
    8.  

  6.  
  7. Apply a liberal amount of lubricant GM P/N 12345001 or equivalent to the camshaft bearing caps.
  8.  
  9. Install the camshaft bearing caps and bolts. Tighten in sequence as follows:
    1. Alternately hand tighten the camshaft bearing cap bolts a few turns at a time until all caps are fully seated.
    2.  
    3. Tighten camshaft bearing cap bolts to 44 inch lbs. (5 Nm).
    4.  
    5. Tighten camshaft bearing cap bolts an additional 30 degrees.

      Click image to see an enlarged view

      Fig. Right cylinder head camshaft bearing cap tightening sequence-4.0L engine

    6.  

  10.  
  11. Align the camshafts.
  12.  
  13. Install the camshaft holding fixture.
    NOTE
    Ensure the camshaft sprockets properly engage the camshaft sprocket drive pins and camshafts.

  14.  
  15. Slide the intake and exhaust camshaft sprockets off the pins of the Secondary Drive Timing chain/Sprocket Holding Fixture Tool J 44213 and onto the pins of the camshafts.
  16.  
  17. Tighten the secondary camshaft drive chain guide upper bolt to 18 ft. lbs. (25 Nm).
  18.  
  19. Install the secondary camshaft drive chain guide upper bolt access plug and tighten to 39 inch lbs. (4.5Nm).
  20.  
  21. Remove the Secondary Drive Timing chain/Sprocket Holding Fixture Tool J 44213 while carefully holding the camshaft sprockets against the camshafts.
  22.  
  23. Install the camshaft sprocket bolts and tighten to 89 ft. lbs. (120 Nm).
  24.  
  25. Verify the camshaft sprocket alignment.
  26.  
  27. Remove the camshaft holding tool.
  28.  
  29. Install or connect the following:

    Camshaft cover and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Cable harness clips at the front of the camshaft cover
     
    Ignition coil cassette and spark plug boots
     
    Nut securing the AIR tube
     
    AIR control valve bracket
     
    AIR vent solenoid electrical connector
     
    Vacuum tubes from the AIR vent solenoid
     
    Positive Crankcase Ventilation (PCV) valve to the camshaft cover
     
    Fuel injector sight shield
     
    Negative battery cable
     

  30.  
  31. Refill the cooling system.
  32.  

 
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