Cavalier, Sunfire 2001-2005

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



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

    Negative battery cable
     
    Accessory drive belt
     
    Drive belt tensioner
     

  4.  
  5. Install an engine support fixture.
  6.  
  7. Remove or disconnect the following:

    Engine mount assembly
     
    Alternator
     
    Power steering pump and move it aside with the lines attached
     
    Oil pan
     
    Crankshaft pulley/hub
     
    Front cover
     

  8.  
  9. Position the No. 1 piston at Top Dead Center (TDC) of the compression stroke so the camshaft and crankshaft sprockets timing marks are aligned.
  10.  
  11. Remove or disconnect the following:

    Timing chain tensioner
     
    Camshaft sprocket and chain as an assembly
     
    Crankshaft sprocket, using a puller

    Click image to see an enlarged view

    Fig. Exploded view of the accessory drive belt tensioner mounting-2.2L (VIN4 ) engine



    Click image to see an enlarged view

    Fig. Align the sprocket timing marks with the alignment tabs on the tensioner during timing chain installation-2.2L (VIN4 ) engine

     

  12.  

To install:

  1. Lubricate the timing chain with clean engine oil.
  2.  
  3. Install the crankshaft sprocket, press it onto the crankshaft.
  4.  
  5. Install the timing chain over the camshaft sprocket, then around the crankshaft sprocket. Be sure the marks on the 2 sprockets are in alignment. Lubricate the thrust surface with Molykote® or equivalent.
  6.  
  7. Install or connect the following:

    Camshaft sprocket. Torque the bolts to 96 ft. lbs. (130 Nm).
     

  8.  
  9. Compress the timing chain tensioner spring. Insert a cotter pin or a nail into the hole in the tensioner to retain the timing chain tensioner shoe.

    Chain tensioner. Torque the bolts to 18 ft. lbs. (24 Nm).
     

  10.  
  11. Remove the cotter pin or nail from the hole in the tensioner.

    Front cover with a new gasket. Torque the bolts to 97 inch lbs. (11 Nm).
     
    Crankshaft pulley/hub. Torque the pulley bolts to 37 ft. lbs. (50 Nm) and the hub bolt to 77 ft. lbs. (105 Nm).
     
    Oil pan with new gaskets. Torque the nuts and bolts to 89 inch lbs. (10 Nm).
     
    Power steering pump. Torque the bolts to 22 ft. lbs. (30 Nm).
     
    Alternator. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Engine mount assembly. Torque the bolts to 55 ft. lbs. (75 Nm).
     

  12.  
  13. Remove the engine support fixture.
  14.  
  15. Install or connect the following:

    Accessory drive belt tensioner. Torque the bolts to 37 ft. lbs. (50 Nm).
     
    Accessory drive belt
     
    Negative battery cable
     

  16.  

2.2L (VIN F) 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 (VIN F) 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 (VIN F) engine



      Click image to see an enlarged view

      Fig. Remove the front cover bolts and cover-2.2L (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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 (VIN F) 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. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Install an engine support.
  8.  
  9. Remove or disconnect the following:

    Coolant surge tank
     
    Accessory drive belt
     
    Upper fasteners from the front cover
     
    Right engine mount and bracket
     
    Right front wheel
     
    Splash shield from the right wheel well
     
    Crankshaft balancer
     
    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 holes in the timing chain housing. The mark on the crankshaft sprocket should align with the mark on the cylinder block. The crankshaft sprocket keyway should point upwards and align with the center line of the cylinder bores. This is the normal timed position.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Make sure that all of the slack in the timing chain is above the tensioner assembly.



    Timing chain guides
     

  14.  

The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward.



Tensioner assembly
 

  1. Mark the crankshaft sprocket and the timing chain outer surface.

    Timing chain
     

  2.  

To install:

  1. Install the intake camshaft sprocket. Torque the bolt to 52 ft. lbs. (70 Nm).
    NOTE
    Install the Special tool J 36008-A through the holes in the camshaft sprockets and into the holes in the timing chain housing. This positions the camshafts for correct 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. Rotate 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 in position 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 coolant pump sprocket and around the crankshaft sprocket.
  6.  
  7. Remove the alignment dowel pin from the intake camshaft. Using tool J 39579, 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. 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 the chain between the intake camshaft sprocket and the crankshaft sprocket, the crankshaft keyway and the cylinder block mark should be aligned. If not aligned, move the chain 1 tooth forward or rearward. Remove the slack and recheck marks.
  12.  
  13. Reload timing chain tensioner assembly to its 0 position as follows:
    1. Insert the tensioner plunger assembly into the tensioner housing.
    2.  
    3. With the tensioner plunger fully extended, turn the complete assembly upside down on a flat surface.
    4.  
    5. Press the bottom of the tensioner housing to compress the plunger into the housing until it is seated.
    6.  
    7. Make sure that the plunger does not extend out of the tensioner housing more than 0.07 in. (1.7mm).
    8.  
    9. Loosely install the tensioner assembly to the timing chain housing.
    10.  

  14.  
  15. Install or connect the following:
    WARNING
    If the timing chain tensioner plunger is not released from the installation position, engine damage will occur upon start up.



    Tensioner shoe on the stud.
     
    Tensioner assembly by applying hand pressure on the timing chain tensioner shoe until the locking tab seats in the stud groove. Tighten the bolts to 89 inch lbs. (10 Nm).
     

  16.  
  17. Release the tensioner plunger by firmly pressing a flat blade tool against the plunger face.
  18.  
  19. Remove tool J 36008-A from the camshaft sprockets.
    1. Rotate crankshaft clockwise 2 full rotations. Align crankshaft keyway with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly.
    2.  

  20.  
  21. Install or connect the following:

    Timing chain guides
     
    New seal lubricated with engine oil
     
    Front cover using new gaskets. Tighten the nuts and bolts to 115 inch lbs. (13 Nm).
     
    Crankshaft balancer. Torque the bolt to 129 ft. lbs. (175 Nm) plus a 90 degree turn.
     
    Right front wheel well splash shield
     
    Wheel
     
    Right engine mount bracket. Torque the bolts to 44 ft. lbs. (60 Nm) plus an additional 60 degree turn.
     
    Right engine mount. Torque the bolts to 55 ft. lbs. (75 Nm).
     

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

    Accessory drive belt
     
    Coolant surge tank
     
    Negative battery cable
     

  26.  
  27. Refill the cooling system and check for leaks.
  28.  

 
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