GM Corsica/Beretta 1988-1996 Repair Guide

Timing Chain and Sprockets

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REMOVAL & INSTALLATION



2.0L and 2.2L Engines

See Figures 1, 2, 3 and 4

  1. Remove the front cover as previously detailed.
  2.  
  3. Place the No. 1 piston at TDC of the compression stroke so that the marks on the camshaft and crankshaft sprockets are in alignment (see illustration).
  4.  



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Fig. Fig. 1: The crankshaft and camshaft sprocket marks must be aligned prior to timing chain removal

  1. Either loosen the timing chain tensioner nut as far as possible without actually removing it, or remove the timing chain tensioner retaining bolt.
  2.  
  3. Remove the camshaft sprocket bolt(s), then remove the sprocket and chain assembly. If the sprocket does not slide from the camshaft easily, a light blow with a soft mallet at the lower edge of the sprocket will dislodge it.
  4.  
  5. Remove the Torx® bolts, then remove the tensioner assembly.
  6.  
  7. Use gear puller, J-22888 or equivalent to remove the crankshaft sprocket.
  8.  



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Fig. Fig. 2: On some vehicles, the tensioner is secured with a retaining bolt



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Fig. Fig. 3: Exploded view of the timing chain, sprockets and camshaft - 2.0L and 2.2L engines

To install:
  1. Install crankshaft sprocket back onto the crankshaft using tool J 5590 or equivalent installation tool.
  2.  
  3. Compress the tensioner spring, and using a suitable tool (such as a cotter pin or nail), insert the tool into the hole (A) as shown in the accompanying figure.
  4.  



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Fig. Fig. 4: Location to insert the pin in the timing chain tensioner

  1. Install the timing chain tensioner and retaining bolts, but do not tighten at this time.
  2.  
  3. Align the crankshaft and camshaft sprocket timing marks with the tab on the tensioner.
  4.  
  5. Install the timing chain over the camshaft sprocket and then around the crankshaft sprocket. Make sure that the marks on the two sprockets are in alignment (see illustration). Lubricate the thrust surface with Molykote® or its equivalent.
  6.  
  7. Align the dowel in the camshaft with the dowel hole in the sprocket and then install the sprocket onto the camshaft. Use the mounting bolt(s) to draw the sprocket onto the camshaft and then tighten to 77 ft. lbs. (105 Nm).
  8.  
  9. Lubricate the timing chain with clean engine oil. Tighten the tensioner retaining bolts to 17 ft. lbs. (23 Nm).
  10.  
  11. Remove the tool used to compress the tensioner spring.
  12.  
  13. Install the timing chain front cover.
  14.  
  15. Fill the cooling system and crankcase with the proper types and amounts of fluids.
  16.  
  17. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels and add if necessary.
  18.  

2.3L Engine

See Figures 5, 6, 7 and 8

Prior to removing the timing chain, review the entire procedure.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the timing chain (front) cover.
  4.  
  5. For 1990-92 vehicles, remove the crankshaft oil slinger.
  6.  
  7. Rotate the crankshaft clockwise, as viewed from front of engine/normal rotation until the camshaft sprockets' timing dowel pin holes line up with the holes in the timing chain housing. The mark on the crankshaft sprocket should line up with the mark on the cylinder block. The crankshaft sprocket keyway should point upwards and line up with the centerline of the cylinder bores. This is the timed position.
  8.  



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Fig. Fig. 5: The sprockets must be properly aligned in the "timed" position - 2.3L engine

  1. Remove the 3 timing chain guides.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Gently pry off timing chain tensioner spring retainer sleeve, then remove the spring.
  6.  

Two styles of tensioner are used. One with a spring post, early production and 1 without a spring post, late production. Both styles are identical in operation and are interchangeable.



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Fig. Fig. 6: Installed view of the tensioner and shoe assembly - 1992 2.3L engine shown



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Fig. Fig. 7: Disassembled view of the timing chain hydraulic tensioner - 1992 2.3L engine shown



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Fig. Fig. 8: Exploded view of the timing chain tensioner mounting - 1994 2.3L engine shown

  1. Remove timing chain tensioner shoe retainer.
  2.  
  3. Make sure all the slack in the timing chain is above the tensioner assembly; remove the chain tensioner shoe. The timing chain must be disengaged from the wear grooves in the tensioner shoe in order to remove the shoe. Slide a prybar under the timing chain while pulling shoe outward.
  4.  
  5. If difficulty is encountered removing chain tensioner shoe, proceed as follows:
    1. Lower the vehicle.
    2.  
    3. Hold the intake camshaft sprocket with a J 36013 or equivalent holding tool, then remove the sprocket bolt and washer.
    4.  
    5. Remove the washer from the bolt and re-thread the bolt back into the camshaft by hand, the bolt provides a surface to push against.
    6.  
    7. Remove intake camshaft sprocket using a 3-jaw puller in the 3 relief holes in the sprocket. Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur.
    8.  

  6.  
  7. Remove tensioner assembly attaching bolts and tensioner.
  8.  


CAUTION
Be careful, as the tensioner piston is spring loaded and could fly out causing personal injury.

  1. For 1990-92 vehicles, remove the chain housing-to-block stud and the timing chain tensioner shoe pivot.
  2.  
  3. Remove the timing chain from the vehicle.
  4.  

Failure to follow this procedure could result in severe engine damage.

To install:
  1. Tighten the intake camshaft sprocket attaching bolt and washer to specification while holding sprocket in place with camshaft sprocket wrench J 36013, or equivalent, if removed.
  2.  
  3. Install camshaft timing alignment pins J 36008 or equivalent through holes in camshaft sprockets into holes in timing chain housing, this positions the camshafts for correct timing.
  4.  
  5. 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. The crankshaft must be rotated 90° clockwise off of 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 top dead center. Do not rotate the crankshaft clockwise to TDC, valve or piston damage could occur.
    4.  

  6.  
  7. Install timing chain over exhaust camshaft sprocket, around idler sprocket and around crankshaft sprocket.
  8.  
  9. Remove the alignment dowel pin from the intake camshaft. Using a dowel pin remover tool 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.
  10.  
  11. Leave the alignment dowel pins installed.
  12.  
  13. With slack removed from chain between intake camshaft sprocket and crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain 1 tooth forward or rearward, remove slack and recheck marks.
  14.  
  15. Tighten chain housing to block stud, timing chain tensioner shoe pivot. Stud is installed under the timing chain. Tighten to 19 ft. lbs. (26 Nm).
  16.  
  17. Reload the timing chain tensioner assembly to its zero position as follows:
    1. Assemble the restraint cylinder, spring and nylon plug into the plunger. Index slot in restraint cylinder with peg in plunger. While rotating the restraint cylinder clockwise, push the restraint cylinder into the plunger until it bottoms. Keep rotating the restraint cylinder clockwise but allow the spring to push it out of the plunger. The pin in the plunger will lock the restraint in the loaded position.
    2.  
    3. Install a special plunger installer tool into plunger assembly.
    4.  
    5. Install the plunger assembly into the tensioner body with the long end toward the crankshaft when installed.
    6.  

  18.  
  19. Install tensioner assembly to chain housing. Recheck plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.
  20.  
  21. Install and tighten timing chain tensioner bolts and tighten to 10 ft. lbs. (14 Nm).
  22.  
  23. Install tensioner shoe and tensioner shoe retainer.
  24.  
  25. Remove the special tool from the plunger and squeeze plunger assembly into tensioner body to unload the plunger assembly.
  26.  
  27. Lower vehicle enough to reach and remove the alignment dowel pins. Rotate crankshaft clockwise 2 full rotations. Align crankshaft timing mark with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly.
  28.  

If the engine is not correctly timed, severe engine damage could occur.

  1. Install 3 timing chain guides and crankshaft oil slinger (if equipped).
  2.  
  3. Install engine front cover.
  4.  
  5. Connect the negative battery cable. Start engine and check for oil leaks.
  6.  

2.8L and 3.1L Engines

See Figures 9, 10 and 11

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Remove the timing chain front cover.
  6.  
  7. Place the No. 1 piston at TDC with the marks on the camshaft and crankshaft sprockets aligned. This is the No. 4 firing position.
  8.  



Click image to see an enlarged view

Fig. Fig. 9: Camshaft and crankshaft sprocket timing mark alignment - 2.8L and 3.1L engines

  1. Remove the bolt(s) that hold the camshaft sprocket to the camshaft. This sprocket is a light press fit on the camshaft and will come off readily. If the sprocket does not come off easily, a light blow on the lower edge of the sprocket with a plastic mallet should dislodge the sprocket. The chain comes off with the camshaft sprocket.
  2.  
  3. Use tool J 5825-A or an equivalent gear puller to remove the crankshaft sprocket.
  4.  



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of the timing chain and related components - 2.8L and 3.1L (VIN T) engines



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Fig. Fig. 11: Exploded view of the timing chain, sprockets and thrust plate - 3.1L (VIN M) engines

To install:
  1. Without disturbing the position of the engine, mount the crankshaft sprocket on the shaft with tool J 38612 or equivalent sprocket installer.
  2.  
  3. Mount the chain over the camshaft sprocket. Arrange the camshaft sprocket in such a way that the timing marks will line up between the shaft centers and the camshaft locating dowel will enter the dowel hole in the cam sprocket.
  4.  
  5. Place the cam sprocket, with its chain mounted over it, in position on the front of the camshaft and pull up with the bolt(s) that hold it to the camshaft. For 2.8L and 3.1L (VIN T) engines, 18 ft. lbs. (25 Nm). For 3.1L (VIN M) engines, tighten the bolt to 74 ft. lbs. (100 Nm)
  6.  
  7. Lubricate the timing chain with clean engine oil.
  8.  
  9. After the sprockets are in place, turn the engine two full revolutions to make certain that the timing marks are in correct alignment between the shaft centers.
  10.  
  11. Install the timing chain front cover.
  12.  
  13. Fill the cooling system and crankcase with the proper types and amounts of fluids.
  14.  
  15. Connect the negative battery cable, then start the engine and check for leaks. Check the fluid levels and add if necessary.
  16.  

See Figures 12, 13 and 14



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Fig. Fig. 12: Remove the timing chain (front) cover from the vehicle



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Fig. Fig. 13: The marks on the sprocket, crankshaft shown (A), must align with the cam sprocket and dampener (B)



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Fig. Fig. 14: After rotating the engine 2 times, the sprocket marks (A) should still align with the dampener marks (B)

 
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