GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Timing Chain Front Cover

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REMOVAL & INSTALLATION



1.8L, 2.0L and 2.2L OHV Engines

See Figure 1

The following procedure requires the use of a special tool.

  1. Remove the engine drive belts (1982-86 vehicles) or the serpentine belt and tensioner (1987-94 vehicles).
  2.  

Although not absolutely necessary, removal of the right front inner fender splash shield will facilitate access to the front cover.

  1. Install engine support fixture J 28467-A, or equivalent.
  2.  
  3. Remove the engine mount assembly.
  4.  
  5. Remove the alternator rear brace, then remove the alternator.
  6.  
  7. Remove the power steering pump, then position it aside with the lines still attached.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the oil pan.
  12.  
  13. Unscrew the center bolt from the crankshaft pulley and slide the pulley and hub from the crankshaft.
  14.  
  15. Unfasten the front cover-to-block bolts and then remove the front cover. If the front cover is difficult to remove, use a plastic mallet to carefully loosen the cover.
  16.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the timing chain front cover - 2.2L engine shown

To install:
  1. The surfaces of the block and front cover must be clean and free of oil. On 1982-86 models, apply a 1 / 8 in. (3mm) wide bead of RTV sealant to the cover. The sealant must be wet to the touch when the bolts are torqued down. On 1987-94 models a gasket is used. Torque the bolts to 6-9 ft. lbs. (8-12 Nm).
  2.  

When applying RTV sealant to the front cover, be sure to keep it out of the bolt holes.

  1. Position the front cover on the block using a centering tool (J-23042) and tighten the screws.
  2.  
  3. Installation of the remaining components is in the reverse order of removal.
  4.  

2.8L and 3.1L Engines

See Figures 2 and 3

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. On 1985-86 models, disconnect the MAP sensor and the EGR solenoid.
  6.  
  7. On 1985-86 models, remove the coolant recovery tank.
  8.  
  9. Remove the serpentine belt adjustment pulley.
  10.  
  11. Remove the alternator and disconnect the electrical wires.
  12.  
  13. Remove the power steering pump bracket.
  14.  
  15. Disconnect the heater pipe at the power steering bracket.
  16.  
  17. Jack up the car and support it safely.
  18.  
  19. Remove the inner splash shield.
  20.  
  21. Remove the air conditioning compressor belt.
  22.  
  23. Remove the flywheel cover at the transaxle.
  24.  
  25. Remove the harmonic balancer with tool J-23523-1 or equivalent.
  26.  

The outer ring (weight) of the harmonic balancer is bonded to the hub with rubber. Breakage may occur if the balancer is hammered back onto the crankshaft. A press or special installation tool is necessary.

  1. Remove the serpentine belt idler pulley.
  2.  
  3. Unfasten the pan-to-front cover bolts and remove the lower cover bolts.
  4.  
  5. Carefully lower the vehicle.
  6.  
  7. Disconnect the radiator hose at the water pump.
  8.  
  9. Remove the heater pipe at the goose neck.
  10.  
  11. Detach the bypass and overflow hoses.
  12.  
  13. Disconnect the canister purge hose.
  14.  
  15. Unfasten the upper front cover bolts and remove the front cover.
  16.  



Click image to see an enlarged view

Fig. Fig. 2: Timing chain front cover assembly mounting - 1985-92 vehicles



Click image to see an enlarged view

Fig. Fig. 3: Timing chain front cover mounting and tightening specifications - 1993-94 3.1L engines

To install:
  1. Clean all the gasket mounting surfaces on the front cover and block and place a new gasket to the front cover sealing surface. Apply a continuous 1 / 8 in. (3mm) wide bead of sealer (1052357 or equivalent) to the oil pan sealing surface of the front cover.
  2.  
  3. Place the front cover on the engine and install the upper front cover bolts.
  4.  
  5. Raise the vehicle and support it safely.
  6.  
  7. Install the lower cover bolts.
  8.  
  9. Install the oil pan to cover screws.
  10.  
  11. Install the serpentine belt idler pulley.
  12.  
  13. Install the harmonic balancer. (See the Harmonic Balancer Removal and Installation procedure.)
  14.  
  15. Install the flywheel cover on the transaxle.
  16.  
  17. Install the air conditioning compressor belt.
  18.  
  19. Install the inner splash shield.
  20.  
  21. Lower the vehicle and install the remainder of the parts in the reverse order of removal.
  22.  

 
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