Cavalier, Sunfire 2001-2005

Camshaft, Bearings & Lifters

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Removal & Installation



2.2L (VIN 4) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil and coolant.
  4.  
  5. Remove or disconnect the following:

    Engine
     
    Accessory drive belt
     
    Alternator
     
    Power steering pump
     
    Drive belt tensioner
     
    Water pump pulley
     
    Crankshaft pulley
     
    Rocker arm cover
     
    Pushrods, by pivoting the rocker arms to the sides, keeping them in order
     
    Cylinder head
     
    Valve lifters, keeping them in order
     
    Front cover
     
    Camshaft timing sprocket
     
    Timing chain
     
    Timing chain tensioner
     
    Camshaft thrust plate
     
    Camshaft Position (CMP) sensor
     
    Camshaft from the block, being sure the lobes do not contact the bearings
     

  6.  

To install:


WARNING
The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.

  1. Install or connect the following:

    Camshaft, being careful not to contact the bearings with the cam lobes
     
    CMP sensor
     
    Camshaft thrust plate. Torque the bolts to 106 inch lbs. (12 Nm).
     
    Timing chain and sprocket. Torque the bolts to 96 ft. lbs. (130 Nm).
     
    Timing chain tensioner. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Front cover. Torque the bolts to 97 inch lbs. (11 Nm).
     
    Valve lifters
     
    Cylinder head. Torque the long bolts to 46 ft. lbs. (63 Nm) and the short bolts to 43 ft. lbs. (58 Nm), plus an additional 90 degree turn on all bolts.
     
    Pushrods
     
    Rocker arms
     

  2.  
  3. Adjust the valve lash after installing the engine.
  4.  
  5. Install or connect the following:

    Rocker arm cover. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Crankshaft pulley. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Water pump pulley. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Drive belt tensioner. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Accessory drive belt
     
    Engine
     

  6.  
  7. Replace the oil filter and refill engine with new oil.
  8.  
  9. Refill the cooling system.
  10.  

2.2L (VIN F) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Camshaft cover
     
    Upper timing chain guide
     

  4.  
  5. Install Camshaft Sprocket Holding Tool J 43665.

    Both the intake and exhaust camshaft sprocket bolts and discard
     

  6.  
  7. Slide the camshaft sprockets forward.

    Click image to see an enlarged view

    Fig. Install Camshaft Sprocket Holding Tool J 43665-2.2L (VIN F) engine



    Click image to see an enlarged view

    Fig. Remove both the intake and exhaust camshaft sprocket bolts and discard-2.2L (VIN F) engine



    Power steering pump bolts and set pump aside
     

  8.  
  9. Mark bearing caps to ensure they are installed in the original position.
    NOTE
    Remove each bolt on each cap one turn at a time until there is no spring tension on the camshaft.



    Bearing caps
     
    Camshaft
     
    Camshaft roller followers
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Remove the bearing caps and camshaft-2.2L (VIN F) engine

     

  10.  

To install:

  1. Lubricate the valve tips.

    Click image to see an enlarged view

    Fig. Lubricate the valve tips-2.2L (VIN F) engine

  2.  
  3. Install or connect the following:

    Hydraulic lash adjusters
     
    Camshaft roller followers
     

  4.  
  5. Make sure that the alignment notches are aligned with the camshaft sprocket.

    Click image to see an enlarged view

    Fig. Make sure that the alignment notches are aligned with the camshaft sprocket-2.2L (VIN F) engine



    Camshaft
     
    Camshaft bearing caps
     

  6.  
  7. Tighten the camshaft bearing cap bolts in 3 steps to 89 inch lbs. (10 Nm).
  8.  
  9. Apply a 0.197 inch (5mm) bead of anaerobic sealer97 in) bead to the rear intake camshaft bearing cap.

    Click image to see an enlarged view

    Fig. Apply a 0.197 inch (5mm) bead of anaerobic sealer97 in) bead to the rear intake camshaft bearing cap-2.2L (VIN F) engine

  10.  
  11. Install or connect the following:

    Rear intake camshaft bearing cap bolts and tighten to 18 ft. lbs. (25 Nm)
     
    Camshaft sprockets onto the camshafts and hand-tighten the NEW camshaft sprocket bolts
     

  12.  
  13. Remove the sprocket holding tool.
  14.  
  15. Tighten the camshaft sprocket bolts to 63 ft. lbs. (85 Nm), then an additional 30 degrees.

    Upper timing chain guide and tighten to 89 in. lbs. (10 Nm).
     
    Power steering pump and tighten the bolts to 19 ft. lbs. (25 Nm).
     
    Camshaft cover
     

  16.  

2.4L Engine
Exhaust Camshaft
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Ignition coil/module assembly
     
    Oil pressure switch electrical connector
     
    Transaxle fluid level indicator tube assembly, (if equipped) from exhaust camshaft cover
     
    Timing chain housing; do not remove from the engine
     
    Exhaust camshaft cover
     
    Exhaust camshaft housing by reversing of the torque sequence
     

  6.  
  7. Press the cover off the housing by threading 4 housing-to-head bolts into the camshaft housing cover tapped holes. Tighten the bolts evenly so the cover does not bind on the dowel pins.
  8.  
  9. Remove the camshaft housing cover.
  10.  
  11. Loosely install a camshaft housing-to-cylinder head bolt to retain the housing during camshaft and lifter removal.
    NOTE
    Note the position of the chain sprocket dowel pin for reassembly.

  12.  
  13. Remove or disconnect the following:

    Lifters
     
    Camshaft
     
    Camshaft housing from the cylinder head
     

  14.  

To install:

  1. Install or connect the following:
    WARNING
    The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.


    NOTE
    The timing chain sprocket dowel pin should be straight up and align with the centerline of the lifter bores.


    NOTE
    Apply thread locking compound to the camshaft housing cover bolt threads.



    Camshaft housing with a new gasket on the cylinder head with 1 bolt loosely to hold it in place
     
    Lifters
     



    Camshaft
     






    Camshaft housing cover with a new gasket. Torque the bolts, in sequence, to 11 ft. lbs. (15 Nm) plus an additional 90 degree turn (except for the 2 rear fuel pipe-to-camshaft housing bolts). Torque the 2 rear bolts to 11 ft. lbs. (15 Nm), plus an additional 30 degree turn.
     
    Timing chain housing
     
    Transaxle fluid level indicator tube assembly to the exhaust camshaft cover
     
    Oil pressure switch electrical connector
     
    Ignition coil/module assembly. Torque the bolts to 11 ft. lbs. (15 Nm) plus an additional 30 degrees.
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

Intake Camshaft
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Leave 2 of the bolts loosely in place to hold the camshaft housing while separating the camshaft cover from the housing.


    NOTE
    The seal must be replaced any time the housing and cover are separated.



    Ignition coil and module assembly
     
    Camshaft Position (CMP) sensor electrical connector
     
    Power steering pump. DO NOT disconnect the lines.
     
    Fuel pressure regulator vacuum line
     
    Fuel rail
     
    Timing chain housing, DO NOT remove from the engine
     
    Intake camshaft housing cover
     
    Intake camshaft housing, by reversing the torque sequence
     



    Intake camshaft oil seal from the camshaft
     
    Camshaft
     



    Camshaft housing from the cylinder head

    Click image to see an enlarged view

    Fig. Exploded view of the camshaft housing, cover and gaskets-2.4L engine

     

  6.  

To install:

  1. Install or connect the following:
    WARNING
    The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.


    NOTE
    The timing chain sprocket dowel pin should be straight up and align with the centerline of the lifter bores.



    Lifters into their bores
     



    Camshaft
     
    Camshaft housing with a new gasket
     
    New intake camshaft seal lubricated with engine oil
     



    Camshaft housing cover with a new gasket. Torque the bolts, in sequence, to 11 ft. lbs. (15 Nm) plus an additional 90 degree turn (except for the 2 rear fuel pipe-to-camshaft housing bolts). Torque the 2 rear bolts to 11 ft. lbs. (15 Nm), plus an additional 30 degree turn.
     
    Timing chain housing and the timing chain
     
    Fuel rail with new injector o-rings
     
    Vacuum line to the fuel pressure regulator
     
    Fuel injector harness connectors
     
    Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Camshaft position sensor
     
    Ignition coil/module assembly. Torque the bolts to 11 ft. lbs. (15 Nm) plus 30 degrees.
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.