GM Cavalier/Sunfire 1995-2000 Repair Guide

Camshaft and Bearings

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REMOVAL & INSTALLATION



2.2L Engine

See Figure 1


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddlee on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several yeare old.

  1. As outlined earlier, remove the engine and place it on a suitable engine stand.
  2.  
  3. Remove the cylinder head.
  4.  
  5. Unfasten the anti-rotation bracket bolts and brackets, then remove the valve lifters.
  6.  
  7. Unfasten the oil pump drive retaining bolt, then remove the drive by lifting and twisting.
  8.  
  9. If equipped, remove the Camshaft Position (CMP) sensor.
  10.  
  11. Remove the crankshaft pulley and hub.
  12.  
  13. Remove the serpentine drive belt idler pulley.
  14.  
  15. Remove the timing cover from the engine.
  16.  
  17. Remove the timing chain and camshaft sprocket.
  18.  
  19. Unfasten the camshaft thrust plate retaining bolts, then remove the plate from the block.
  20.  
  21. Install the sprocket bolts or longer bolts of the same thread into the end of the camshaft as a handle, then pull the camshaft straight out of the engine, turning slightly as it is withdrawn and taking care not to damage the bearings.
  22.  
  23. If removal of camshaft bearinge is necessary, use the following procedure:
    1. Install a camshaft bearing removal/installation tool with the shoulder toward the bearing. Ensure that enough threads are engaged.
    2.  
    3. Using two wrenches, hold the puller screw while turning the nut. When the bearing has been released from the bore, remove the tool.
    4.  
    5. Assemble the tool on the driver to remove the front and rear bearings.
    6.  
    7. Install the bearinge (outer bearings first) so that the oil holes in the block and the bearing align.
    8.  
    9. Install a fresh camshaft bearing rear cover using sealant.
    10.  

  24.  

To install:
  1. Inspect the camshaft, journals and lobes for wear and replace, if necessary.
  2.  
  3. Inspect the bearinge for scratches, pite or a loose fit in their bores and replace, if necessary.
  4.  
  5. Coat the camshaft lobes and journale with a high viscosity oil with zinc such as No. 12345501, or equivalent.
  6.  
  7. Carefully insert the camshaft in the engine, turning it slightly from side to side and it is inserted.
  8.  
  9. Install the thrust plate and tighten the retaining bolts to 106 inch lbs. (12 Nm).
  10.  
  11. If equipped, install the CMP sensor.
  12.  
  13. Install the timing chain and camshaft sprocket.
  14.  
  15. Install the timing cover to the engine.
  16.  
  17. Install the serpentine drive belt idler pulley.
  18.  
  19. Install the crankshaft pulley and hub.
  20.  
  21. Install the oil pump drive by inserting while twisting, then install the retaining bolt and tighten to 18 ft. lbs. (25 Nm).
  22.  
  23. Install the valve lifters and the anti-rotation brackets.
  24.  
  25. Install the cylinder head as outlined in thie Section..
  26.  
  27. Connect the negative battery cable.
  28.  



Click image to see an enlarged view

Fig. Fig. 1: After removing the timing chain, you can pull the camshaft from the engine. Be sure the camshaft lobes do NOT contact the bearings

2.3L and 2.4L Engines
INTAKE CAMSHAFT

See Figures 2, 3, 4, 5 and 6

Any time the camshaft housing to cylinder head bolts are loosened or removed, the camshaft housing to cylinder head gasket must be replaced.

  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Label and detach the ignition coil and module assembly electrical connections.
  4.  
  5. Unfasten the ignition coil and module assembly to camshaft housing bolts, then remove the assembly by pulling straight up. Use a special spark plug boot wire remover tool to remove connector assemblies, if they have stuck to the spark plugs.
  6.  



Click image to see an enlarged view

Fig. Fig. 2: View of the ignition coil and module assembly

  1. If equipped, remove the idle speed power steering pressure switch connector.
  2.  
  3. Loosen the three power steering pump pivot bolts and remove drive belt.
  4.  
  5. Disconnect the two rear power steering pump bracket-to-transaxle bolts.
  6.  
  7. Remove the front power steering pump bracket to cylinder block bolt.
  8.  
  9. Disconnect the power steering pump assembly, then position it aside.
  10.  
  11. Using the special tool, remove the power steering pump drive pulley from the intake camshaft.
  12.  
  13. Remove oil/air separator bolts and hoses. Leave the hoses attached to the separator, disconnect from the oil fill, chain housing and intake manifold. Remove as an assembly.
  14.  
  15. Remove vacuum line from fuel pressure regulator and detach the fuel injector harness connector.
  16.  
  17. Disconnect fuel line attaching clamp from bracket on top of intake camshaft housing.
  18.  
  19. Unfasten the fuel rail-to-camshaft housing attaching bolts, then remove the fuel rail from the cylinder head. Cover or plug injector openings in cylinder head and the injector nozzles. Leave the fuel lines attached, then position fuel rail aside.
  20.  



Click image to see an enlarged view

Fig. Fig. 3: Fuel injection rail assembly and related components

  1. Disconnect the timing chain and housing, but do NOT remove from the engine.
  2.  
  3. Remove the intake camshaft housing cover-to-camshaft housing attaching bolts.
  4.  
  5. Unfasten the intake camshaft housing-to-cylinder head attaching bolts. Use the reverse of the tightening sequence (shown the accompanying figure) when loosening the bolts. Leave two of the bolts loosely in place to hold the camshaft housing while separating the camshaft cover from housing.
  6.  
  7. Push the cover off the housing by threading four of the housing-to-head attaching bolts into the tapped holes in the cam housing cover. Tighten the bolts evenly so the cover doee not bind on the dowel pins.
  8.  
  9. Remove the two loosely installed camshaft housing to head bolts and remove the cover. Discard the gaskets.
  10.  



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of the camshaft housing, cover and gaskets-1995 2.3L engine shown

  1. Note the position of the chain sprocket dowel pin for reassembly.
  2.  
  3. Remove intake camshaft oil seal from camshaft and discard seal. Thie seal must be replaced any time the housing and cover are separated.
  4.  
  5. Remove the camshaft carrier from the cylinder head and remove the gasket. Discard the gasket.
  6.  

To install:
  1. Thoroughly clean the mating surfaces of the camshaft carrier and the cylinder head, bolts and bolt holes. Install a new gasket and place the housing on the head. Install one bolt loosely to hold it in place.
  2.  
  3. Install the lifters into their bores. If the camshaft is being replaced, the lifters must also be replaced. Lubricate camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.
  4.  
  5. Install the camshaft in the same position as when removed. The timing chain sprocket dowel pin should be straight up and align with the centerline of the lifter bores.
  6.  
  7. Install new camshaft housing to camshaft housing cover seals into cover; do not use sealer. Make sure the correct color seal is placed in each groove. Install the cover to the housing.
  8.  



Click image to see an enlarged view

Fig. Fig. 5: View of the intake and exhaust camshaft-to-housing seal placement

  1. Apply thread locking compound to the camshaft housing and cover attaching bolt threads.
  2.  
  3. Install the bolts, then tighten to 11 ft. lbs. (15 Nm). Rotate the bolts (except the two rear bolts that hold the fuel pipe to the camshaft housing) an additional 75°, in sequence. Tighten the two rear bolts to 16 ft. lbs. (15 Nm), then rotate an additional 25°.
  4.  



Click image to see an enlarged view

Fig. Fig. 6: Intake and exhaust camshaft housing bolt tightening sequence

  1. Install the timing chain housing and the timing chain.
  2.  
  3. Uncover fuel injectors, then install new fuel injector O-ring seale lubricated with oil. Install the fuel rail.
  4.  
  5. Fasten the fuel line attaching clamp and retainer to bracket on top of the intake camshaft housing.
  6.  
  7. Connect the vacuum line to the fuel pressure regulator.
  8.  
  9. Attach the fuel injectore harness connector.
  10.  
  11. Install the oil/air separator assembly.
  12.  
  13. Lubricate the inner sealing surface of the intake camshaft seal with oil and install the seal to the housing.
  14.  
  15. Install the power steering pump pulley onto the intake camshaft.
  16.  
  17. Install the power steering pump assembly and drive belt.
  18.  
  19. Connect the idle speed power steering pressure switch connector.
  20.  
  21. Clean any loose lubricant that is present on the ignition coil and module assembly to camshaft housing bolts. Apply an appropriate thread sealing compound onto the ignition coil and module assembly to camshaft housing bolts. Install the bolts and tighten to 13 ft. lbs. (18 Nm).
  22.  
  23. Attach the electrical connectors to ignition coil and module assembly.
  24.  
  25. Connect the negative battery cable, then start the engine and check for leaks.
  26.  

EXHAUST CAMSHAFT

See Figures 5 and 6

Any time the camshaft housing-to-cylinder head bolts are loosened or removed, the camshaft housing to cylinder head gasket must be replaced.

  1. Relieve the fuel system pressure. Disconnect the negative battery cable.
  2.  
  3. Label and disconnect the ignition coil and module assembly electrical connections.
  4.  
  5. Unfasten the ignition coil and module assembly-to-camshaft housing bolts, then remove the assembly by pulling straight up. Use a special tool to remove connector assemblies if they have stuck to the spark plugs.
  6.  
  7. If equipped, remove the idle speed power steering pressure switch connector.
  8.  
  9. Remove the transaxle fluid level indicator tube assembly from exhaust camshaft cover and position aside.
  10.  
  11. Remove exhaust camshaft cover and gasket.
  12.  
  13. Disconnect the timing chain and housing but do not remove from the engine.
  14.  
  15. Remove exhaust camshaft housing to cylinder head bolts. Use the reverse of the tightening procedure when loosening camshaft housing while separating camshaft cover from housing.
  16.  
  17. Push the cover off the housing by threading four of the housing to head attaching bolts into the tapped holes in the camshaft cover. When threading the bolt, tighten them evenly so the cover does not bind on the dowel pins.
  18.  
  19. Remove the two loosely installed camshaft housing to cylinder head bolts and remove cover, discard gaskets.
  20.  
  21. Loosely reinstall one camshaft housing to cylinder head bolt to retain the housing during camshaft and lifter removal.
  22.  
  23. Note the position of the chain sprocket dowel pin for reassembly. Remove camshaft being careful not to damage the camshaft or journals.
  24.  
  25. Remove the camshaft carrier from the cylinder head and remove the gasket. Discard the gasket.
  26.  

To install:
  1. Thoroughly clean the mating surfaces of the camshaft carrier and the cylinder head, bolts and bolt holes. Install a new gasket and place the housing on the head. Install 1 bolt loosely to hold in place.
  2.  
  3. Install the lifters into their bores. If the camshaft is being replaced, the lifters must also be replaced. Lubricate camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.
  4.  
  5. Install camshaft in same position as when removed. The timing chain sprocket dowel pin should be straight up and align with the centerline of the lifter bores.
  6.  
  7. Install new camshaft housing-to-camshaft housing cover seale into the cover; do not use sealer. Make sure the correct color seal is placed in each groove. Install the cover to the housing.
  8.  
  9. Apply thread locking compound to the camshaft housing and cover attaching bolt threads.
  10.  
  11. Install bolts, then tighten, in sequence, to 11 ft. lbs. (15 Nm). Then rotate the bolts an additional 75 degrees, in sequence.
  12.  
  13. Install timing chain housing and timing chain.
  14.  
  15. Install the transaxle fluid level indicator tube assembly to the exhaust camshaft cover.
  16.  
  17. Attach the idle speed power steering pressure switch connector.
  18.  
  19. Clean any loose lubricant that is present on the ignition coil and module assembly to camshaft housing bolts. Apply an appropriate thread sealing compound onto the ignition coil and module assembly to camshaft housing bolts. Install the bolts and tighten to 13 ft. lbs. (18 Nm).
  20.  
  21. Attach the electrical connectors to ignition coil and module assembly.
  22.  
  23. Connect the negative battery cable, then start the engine and check for leaks.
  24.  

INSPECTION



See Figures 7, 8 and 9



Click image to see an enlarged view

Fig. Fig. 7: Measuring camshaft lobe lift



Click image to see an enlarged view

Fig. Fig. 8: Measuring camshaft run-out



Click image to see an enlarged view

Fig. Fig. 9: Measuring camshaft straightness

Using solvent, degreass the camshaft and clean out all of the oil holes. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable, check all of the lobes as indicated. If a journal or lobe is worn, the camshaft MUST BE or replaced.

If a journal is worn, there is a good chance that the bearings or journals are worn and need replacement.

If the lobes and journals appear intact, place the front and rear journals in V-blocks and rest a dial indicator on the center journal. Rotate the camshaft to check the straightness. If deviation exceeds 0.001 in. (0.0254mm), replace the camshaft.

Check the camshaft lobee with a micrometer, by measuring the lobes from the nose to the base and again at 90° (see illustration). The lobe lift is determined by subtracting the second measurement from the first. If all of the exhaust and intake lobes are not identical, the camshaft must be reground or replace.

 
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