Canyon, Colorado 2004-2005

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Number 1 cylinder spark plug
     
    Intake manifold
     
    Ignition coils
     
    Engine coolant temperature (ECT) sensor electrical connector from camshaft cover
     
    Fuel injector connector from camshaft cover
     
    Heated oxygen sensor (HO2S) connector from camshaft cover
     
    Fuel pressure regulator screw
     
    Camshaft cover
     
    Camshaft position (CMP) sensor
     
    Water pump
     

  8.  
  9. Remove the service slot plug and install Flywheel Holding Tool EN-46547 into the flywheel teeth.

    Click image to see an enlarged view

    Fig. Use Special tool EN-46547 to prevent the flywheel from turning.

  10.  
  11. Remove the crankshaft balancer bolt and discard.
  12.  
  13. Install Crankshaft end protector J-41816-2 into the end of the crankshaft and remove the crankshaft balancer using a 3-jaw puller.

    Click image to see an enlarged view

    Fig. Remove the crankshaft balancer using a suitable puller after installing End Protector J-41816-2.

  14.  
  15. Remove or disconnect the following:

    Drive belt tensioner
     
    Power steering pump
     
    Oil pan
     
    Oil pump pipe and screen assembly
     
    7mm center front cover bolt
     
    Remaining engine front cover bolts
     

  16.  
  17. Install 2 bolts into the threaded holes to act as jack screws and tighten evenly to release the front cover.
  18.  
  19. Rotate the crankshaft clockwise until the no. 1 cylinder is at TDC on the compression stroke. The word DELPHI on the camshaft position actuator will be parallel with the cylinder head surface.
  20.  
  21. Install camshaft locking tool J-44221 to the rear of the camshafts.
  22.  
  23. Release the tension on the timing chain by moving the tensioner shoe in by hand.
  24.  
  25. Place a tee in the tensioner to hold the shoe in place.
  26.  
  27. Remove the top timing chain guide.
  28.  
  29. Remove the exhaust camshaft position actuator bolt and actuator.
  30.  
  31. Remove the intake camshaft sprocket bolt and sprocket.
  32.  
  33. Remove the timing chain.
  34.  
  35. Remove the crankshaft sprocket.
  36.  

To install:

  1. Install the crankshaft sprocket.
  2.  
  3. Install the intake camshaft sprocket on the timing chain and align the dark link on the timing chain with the timing mark on the intake sprocket as shown.
  4.  
  5. Feed the timing chain through the opening in the cylinder head.
  6.  
  7. Install the timing chain on the crankshaft sprocket and align the dark link of the timing chain with the timing mark on the crankshaft sprocket.
  8.  
  9. Install a new intake camshaft sprocket bolt and washer and tighten the bolt to 15 ft. lbs. (20 Nm), plus an additional 100°.
  10.  
  11. Install the exhaust camshaft actuator on the timing chain with the word DELPHI facing horizontal to the cylinder head surface and the dark link of the timing chain aligned with the timing mark on the camshaft actuator sprocket.
    NOTE
    Ensure the alignment pin is engaged between the camshaft and exhaust camshaft actuator sprocket.

  12.  
  13. Install the exhaust camshaft actuator onto the exhaust camshaft.
    NOTE
    Rotate the camshaft actuator clockwise until it stops. This will fully advance the actuator. Engine damage may occur if the actuator is not fully advanced.

  14.  
  15. Install a new exhaust camshaft sprocket bolt and washer and tighten the bolt to 18 ft. lbs. (25 Nm), plus an additional 135°.
  16.  
  17. Remove the tee in the timing chain tensioner to tension the timing chain.
  18.  
  19. Remove the camshaft locking tool from the camshafts.
  20.  
  21. The dark links should be aligned with the camshaft and crankshaft sprockets as shown.

    Click image to see an enlarged view

    Fig. Aligning timing chain dark links with camshaft and crankshaft sprockets-Canyon & Colorado



    Click image to see an enlarged view

    Fig. Front cover sealant application-Canyon & Colorado

  22.  
  23. Thread alignment pins into the engine block to aid front cover installation.
  24.  
  25. Apply sealant to the front cover surfaces as shown.
  26.  
  27. Align the oil pump with the crankshaft sprocket splines.
  28.  
  29. Install the front cover over the alignment pins, and loosely install the front cover bolts.
  30.  
  31. Remove the alignment pins and install the remaining 2 bolts.
  32.  
  33. Tighten the front cover bolts to 89 inch lbs. (10 Nm).
  34.  
  35. Tighten the small center cover bolt to 71 inch lbs. (8 Nm).
  36.  
  37. Install clean engine oil to the outside diameter of the new front crankshaft oil seal.
  38.  
  39. Using a seal installer, install the front oil seal.
  40.  
  41. Install a new o-ring to the oil pump pipe screen assembly and install the oil pump pipe screen.
  42.  
  43. Apply sealant to the oil pump pipe bolt threads and tighten the bolts to 89 inch lbs. ( 10 Nm).
  44.  
  45. Install or connect the following:

    Oil pan
     
    Power steering pump
     
    Drive belt tensioner
     
    Crankshaft damper and tighten new bolt and tighten to 111 ft. lbs. (150 Nm), plus an additional 180°.
     

  46.  
  47. Remove the flywheel locking tool.
  48.  
  49. Install or connect the following:

    Flywheel access service plug
     
    Water pump
     
    Accessory drive belt
     
    Cooling fan
     
    Negative battery cable
     

  50.  
  51. Fill the engine with coolant and oil.
  52.  
  53. Start the engine and check for leaks.
  54.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Number 1 cylinder spark plug
     
    Intake manifold
     
    Ignition coils
     
    Engine coolant temperature (ECT) sensor electrical connector from camshaft cover
     
    Fuel injector connector from camshaft cover
     
    Heated oxygen sensor (HO2S) connector from camshaft cover
     
    Fuel pressure regulator screw
     
    Camshaft cover
     
    Camshaft position (CMP) sensor
     
    Water pump
     

  8.  
  9. Remove the service slot plug and install Flywheel Holding Tool EN-46547 into the flywheel teeth.

    Click image to see an enlarged view

    Fig. Use Special tool EN-46547 to prevent the flywheel from turning.

  10.  
  11. Remove the crankshaft balancer bolt and discard.
  12.  
  13. Install Crankshaft end protector J-41816-2 into the end of the crankshaft and remove the crankshaft balancer using a 3-jaw puller.

    Click image to see an enlarged view

    Fig. Remove the crankshaft balancer using a suitable puller after installing End Protector J-41816-2.

  14.  
  15. Remove or disconnect the following:

    Drive belt tensioner
     
    Power steering pump
     
    Oil pan
     
    Oil pump pipe and screen assembly
     
    7mm center front cover bolt
     
    Remaining engine front cover bolts
     

  16.  
  17. Install 2 bolts into the threaded holes to act as jack screws and tighten evenly to release the front cover.
  18.  
  19. Rotate the crankshaft clockwise until the no. 1 cylinder is at TDC on the compression stroke. The word DELPHI on the camshaft position actuator will be parallel with the cylinder head surface.
  20.  
  21. Install camshaft locking tool J-44221 to the rear of the camshafts.
  22.  
  23. Release the tension on the timing chain by moving the tensioner shoe in by hand.
  24.  
  25. Place a tee in the tensioner to hold the shoe in place.
  26.  
  27. Remove the top timing chain guide.
  28.  
  29. Remove the exhaust camshaft position actuator bolt and actuator.
  30.  
  31. Remove the intake camshaft sprocket bolt and sprocket.
  32.  
  33. Remove the timing chain.
  34.  
  35. Remove the crankshaft sprocket.
  36.  

To install:

  1. Install the crankshaft sprocket.
  2.  
  3. Install the intake camshaft sprocket on the timing chain and align the dark link on the timing chain with the timing mark on the intake sprocket as shown.
  4.  
  5. Feed the timing chain through the opening in the cylinder head.
  6.  
  7. Install the timing chain on the crankshaft sprocket and align the dark link of the timing chain with the timing mark on the crankshaft sprocket.
  8.  
  9. Install a new intake camshaft sprocket bolt and washer and tighten the bolt to 15 ft. lbs. (20 Nm), plus an additional 100°.
  10.  
  11. Install the exhaust camshaft actuator on the timing chain with the word DELPHI facing horizontal to the cylinder head surface and the dark link of the timing chain aligned with the timing mark on the camshaft actuator sprocket.
    NOTE
    Ensure the alignment pin is engaged between the camshaft and exhaust camshaft actuator sprocket.

  12.  
  13. Install the exhaust camshaft actuator onto the exhaust camshaft.
    NOTE
    Rotate the camshaft actuator clockwise until it stops. This will fully advance the actuator. Engine damage may occur if the actuator is not fully advanced.

  14.  
  15. Install a new exhaust camshaft sprocket bolt and washer and tighten the bolt to 18 ft. lbs. (25 Nm), plus an additional 135°.
  16.  
  17. Remove the tee in the timing chain tensioner to tension the timing chain.
  18.  
  19. Remove the camshaft locking tool from the camshafts.
  20.  
  21. The dark links should be aligned with the camshaft and crankshaft sprockets as shown.

    Click image to see an enlarged view

    Fig. Aligning timing chain dark links with camshaft and crankshaft sprockets-Canyon & Colorado



    Click image to see an enlarged view

    Fig. Front cover sealant application-Canyon & Colorado

  22.  
  23. Thread alignment pins into the engine block to aid front cover installation.
  24.  
  25. Apply sealant to the front cover surfaces as shown.
  26.  
  27. Align the oil pump with the crankshaft sprocket splines.
  28.  
  29. Install the front cover over the alignment pins, and loosely install the front cover bolts.
  30.  
  31. Remove the alignment pins and install the remaining 2 bolts.
  32.  
  33. Tighten the front cover bolts to 89 inch lbs. (10 Nm).
  34.  
  35. Tighten the small center cover bolt to 71 inch lbs. (8 Nm).
  36.  
  37. Install clean engine oil to the outside diameter of the new front crankshaft oil seal.
  38.  
  39. Using a seal installer, install the front oil seal.
  40.  
  41. Install a new o-ring to the oil pump pipe screen assembly and install the oil pump pipe screen.
  42.  
  43. Apply sealant to the oil pump pipe bolt threads and tighten the bolts to 89 inch lbs. ( 10 Nm).
  44.  
  45. Install or connect the following:

    Oil pan
     
    Power steering pump
     
    Drive belt tensioner
     
    Crankshaft damper and tighten new bolt and tighten to 111 ft. lbs. (150 Nm), plus an additional 180°.
     

  46.  
  47. Remove the flywheel locking tool.
  48.  
  49. Install or connect the following:

    Flywheel access service plug
     
    Water pump
     
    Accessory drive belt
     
    Cooling fan
     
    Negative battery cable
     

  50.  
  51. Fill the engine with coolant and oil.
  52.  
  53. Start the engine and check for leaks.
  54.  

 
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