HHR 2006-2008

Timing Chain & Sprockets

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Removal & Installation



2.0L Engine
  1. Remove the hood.
  2.  
  3. Remove the #1 cylinder spark plug.
  4.  
  5. Rotate the crankshaft in the engine rotational direction clockwise, until the #1 piston is at top dead center (TDC) on the compression stroke.
  6.  
  7. Remove the camshaft cover.
  8.  
  9. Remove the engine front cover.
  10.  
  11. Remove the upper timing chain guide bolts and guide.
    WARNING
    The timing chain tensioner must be removed to unload chain tension before the timing chain is removed. If it is not, the timing chain will become cocked and it will be difficult to remove.



    Click image to see an enlarged view

    Fig. Timing chain guide bolts and guide removal

  12.  
  13. Remove the timing chain tensioner.

    Click image to see an enlarged view

    Fig. Timing chain tensioner removal

  14.  
  15. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
  16.  
  17. Remove and discard the exhaust camshaft actuator bolt.
  18.  
  19. Remove the exhaust camshaft actuator from the camshaft and timing chain.

    Click image to see an enlarged view

    Fig. Camshaft actuator (1,3) bolt (2)

  20.  
  21. Remove the timing chain tensioner guide bolt and guide.

    Click image to see an enlarged view

    Fig. Timing chain tensioner guide bolt and guide

  22.  
  23. Remove the fixed timing chain guide access plug.

    Click image to see an enlarged view

    Fig. Fixed timing chain guide access plug

  24.  
  25. Remove the fixed timing chain guide bolts and guide.
  26.  
  27. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
  28.  
  29. Remove and discard the intake camshaft actuator bolt.
  30.  
  31. Remove the intake camshaft actuator, and the timing chain through the top of the cylinder head.
  32.  
  33. Remove the timing chain crankshaft sprocket.
  34.  
  35. If replacing the balance shaft timing chain and sprocket, perform the following steps, if not proceed to step 10 in the installation procedure.
  36.  
  37. Remove the balance shaft drive chain tensioner bolts and tensioner.
  38.  
  39. Remove the adjustable balance shaft chain guide bolt and guide.
  40.  
  41. Remove the small balance shaft drive chain guide bolts and guide.
  42.  
  43. Remove the upper balance shaft drive chain guide bolts and guide.
    NOTE
    It may ease removal of the balance shaft drive chain to get all the slack in the chain between the crankshaft and water pump sprockets.

  44.  
  45. Remove the balance shaft drive chain.
  46.  

To install:

  1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10.
  2.  
  3. Install the balance shaft drive sprocket.
    WARNING
    If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise.

  4.  
  5. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket.
  6.  
  7. There are three colored links on the chain. Two are chrome and one is copper. Use the following steps in order to line up the links with the sprockets:
    1. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (Approximately 6 o'clock position on the sprocket.)
    2.  
    3. Place the chain (7) on the water pump drive sprocket. The alignment is not critical.
    4.  
    5. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.

      Click image to see an enlarged view

      Fig. Timing chain alignment

    6.  

  8.  
  9. Install the upper balance shaft drive chain guide and bolts, tighten bolts to 11ft. lbs. (15 Nm).
  10.  
  11. Install the small balance shaft drive chain guide and bolts, tighten bolts to 11ft. lbs. (15 Nm).
  12.  
  13. Install the adjustable balance shaft chain guide and bolt, tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Reset the timing chain tensioner by performing the following steps:
    1. Rotate the tensioner plunger 90 degrees in its bore and compress the plunger.
    2.  
    3. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
    4.  

  16.  
  17. Install the balance shaft drive chain tensioner and bolts.
  18.  
  19. Remove the paper clip from the balance shaft drive chain tensioner.
  20.  
  21. Ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at top dead center (TDC), crankshaft key at 12 o'clock.
    WARNING
    There are 3 colored links on the timing chain. 2 links are of matching color, and 1 link is of a unique color. Use the following procedure to line up the links with the actuators. Orient the chain so that the colored links are visible.



    Click image to see an enlarged view

    Fig. Camshaft alignment

  22.  
  23. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing out.
  24.  
  25. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link

    Click image to see an enlarged view

    Fig. Camshaft actuator and timing chain mark alignment

  26.  
  27. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses.
  28.  
  29. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
  30.  
  31. Hand tighten the new intake camshaft actuator bolt.
  32.  
  33. Route the timing chain around the crankshaft sprocket and line up the first matching colored link with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.

    Click image to see an enlarged view

    Fig. Crankshaft sprocket and timing chain mark alignment

  34.  
  35. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
  36.  
  37. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt.

    Click image to see an enlarged view

    Fig. Installation of the adjustable timing chain guide

  38.  
  39. Tighten the adjustable timing chain guide bolt to 89 inch. lbs. (10 Nm).
    NOTE
    Always install new actuator bolts.

  40.  
  41. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.

    Click image to see an enlarged view

    Fig. Camshaft actuator and timing chain mark alignment

  42.  
  43. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
  44.  
  45. Using a 23 mm open end wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
  46.  
  47. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
  48.  
  49. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.

    Click image to see an enlarged view

    Fig. Timing chain, colored links, and marks

  50.  
  51. Install the fixed timing chain guide and bolts. Tighten the fixed timing chain guide bolts to 106 inch. lbs. 12 Nm).
  52.  
  53. Install the upper timing chain guide and bolts, tighten to 89 inch. lbs. (10 Nm).
  54.  
  55. Reset the timing chain tensioner by performing the following steps:
    1. Remove the snap ring.
    2.  
    3. Remove the piston assembly from the body of the timing chain tensioner.
    4.  
    5. Install the J 45027-2 (2) into a vise.
    6.  
    7. Install the notch end of the piston assembly into the J 45027-2 (2).
    8.  
    9. Using the J 45027-1 (1), turn the ratchet cylinder into the piston
    10.  
    11. Reinstall the piston assembly into the body of the tensioner.
    12.  
    13. Install the snap ring.

      Click image to see an enlarged view

      Fig. Timing chain tensioner and tools shown for resetting

    14.  

  56.  
  57. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
  58.  
  59. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
    WARNING
    Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak.

  60.  
  61. Install the timing chain tensioner assembly and tighten to 55 ft. lbs. (75 Nm).

    Click image to see an enlarged view

    Fig. Timing chain tensioner installation

  62.  
  63. The timing chain tensioner is released by compressing it 0.079 inch (2 mm), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
  64.  
  65. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt.
  66.  
  67. Tighten the intake camshaft position actuator bolt to 22 ft. lbs. (30 Nm). plus an additional 100 degrees using a angle meter.
  68.  
  69. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt.
  70.  
  71. Tighten the intake camshaft position actuator bolt to 22 ft. lbs. (30 Nm). plus an additional 100 degrees using a angle meter.
  72.  
  73. Install the timing chain oiling nozzle, and tighten to 89 inch. lbs. ( 10 Nm).
  74.  
  75. Apply sealant compound to the thread of the timing chain guide bolt access hole plug.
  76.  
  77. Install the timing chain guide bolt access hole plug and tighten to 66ft. lbs. 90 Nm).
  78.  
  79. Install the engine front cover.
  80.  
  81. Install the camshaft cover.
  82.  
  83. Install the #1 cylinder spark plug.
  84.  
  85. Install the hood.
  86.  

2.2L & 2.4L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshaft cover.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the timing chain cover.
  8.  
  9. Lower the vehicle.
    NOTE
    To rotate the camshaft, use a 24 mm open-end wrench on the camshaft flats. Camshaft should be rotated in a clockwise direction only, facing camshaft sprockets from the passenger side of the vehicle.



    Click image to see an enlarged view

    Fig. To rotate the camshaft, use a 24 mm open-end wrench on the camshaft flats



    Click image to see an enlarged view

    Fig. Locate the No. 1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position)

  10.  
  11. Locate the No. 1 piston to approximately 60° before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position).
  12.  
  13. Remove the spark plugs. This will ease the rotation effort.

    Click image to see an enlarged view

    Fig. Timing chain tensioner

  14.  
  15. Remove the timing chain tensioner.

    Click image to see an enlarged view

    Fig. Fixed timing chain guide access plug

  16.  
  17. Remove the fixed timing chain guide access plug.
  18.  
  19. Remove the fixed timing chain guide.
  20.  
  21. Remove the upper timing chain guide.
  22.  
  23. Use a 24mm wrench to hold the camshafts from turning.
  24.  
  25. Remove the exhaust camshaft sprocket bolt and discard.
  26.  
  27. Remove the exhaust camshaft sprocket.
  28.  
  29. Remove the timing chain tensioner guide.
  30.  
  31. Remove the intake camshaft sprocket bolt and discard.
  32.  
  33. Remove the intake camshaft sprocket.
  34.  
  35. Remove the timing chain through the top of the cylinder head.
  36.  
  37. Remove the crankshaft sprocket.
  38.  
  39. Remove the oil nozzle and bolt.
  40.  
  41. Remove the balance shaft drive chain tensioner.
  42.  
  43. Remove the adjustable balance shaft chain guide.
  44.  
  45. Remove the small balance shaft drive chain guide.
  46.  
  47. Remove the upper balance shaft drive chain guide.
    NOTE
    It may ease removal of the balance shaft drive chain to get all of the slack in the chain between the crankshaft and water pump sprockets.

  48.  
  49. Remove the balance shaft drive chain.
  50.  

To install:


WARNING
If the balance shafts are not properly timed to the engine, the engine may vibrate and make noise.

  1. Install the upper balance shaft chain guide. Tighten the upper balance shaft chain guide bolts to 11 ft. lbs. (15 Nm).

    Click image to see an enlarged view

    Fig. Balance shaft chain installation

  2.  
  3. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. Use the following procedure to line up the links with the sprockets: Orient the chain so that the copper colored and chrome links are visible.
    1. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
    2.  
    3. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket. (approximately 5 o'clock position on the crank sprocket).
    4.  
    5. Place the chain (3) on the water pump drive sprocket (alignment is not critical).
    6.  
    7. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.
    8.  

  4.  
  5. Install the small balance shaft chain guide.
  6.  
  7. Tighten the balance shaft chain guide bolts. Tighten the chain guide bolts to 11 ft. lbs. (15 Nm).
  8.  
  9. Install the adjustable balance shaft drive chain guide. Tighten the chain guide bolts to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. 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

  10.  
  11. Turn the tensioner plunger 90° 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.
  12.  
  13. Install the timing chain tensioner.
  14.  
  15. Tighten the chain tensioner bolts. Tighten the chain tensioner bolts to 89 inch lbs. (10 Nm).
  16.  
  17. Remove the paper clip from the balance shaft drive chain tensioner.
  18.  
  19. Install the oil nozzle and bolt. Tighten the oil nozzle bolt to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Install the crankshaft sprocket with timing mark at the 5 o'clock position

  20.  
  21. Install the crankshaft sprocket with timing mark at the 5 o'clock position.

    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)

  22.  
  23. 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).

    Click image to see an enlarged view

    Fig. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position

  24.  
  25. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position.
    NOTE
    Always install NEW sprocket bolts.

  26.  
  27. Hand tighten a NEW intake camshaft sprocket bolt.
  28.  
  29. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark.
  30.  
  31. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.
  32.  
  33. Install the timing chain tensioner guide through the opening in the top of the cylinder head. Tighten the timing chain tensioner guide bolt to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position

  34.  
  35. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position.
  36.  
  37. Use a 24mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.
    NOTE
    Always install NEW sprocket bolts.

  38.  
  39. Hand-tighten the NEW exhaust camshaft sprocket bolt.
  40.  
  41. Install the fixed timing chain guide. Tighten the fixed timing chain bolts to 89 inch lbs. (10 Nm).
  42.  
  43. Apply sealant, GM P/N 12378521 (Canadian P/N 88901148) compound to thread and install the timing chain guide bolt access hole plug. Tighten the chain guide plug to 59 ft. lbs. (90 Nm).
  44.  
  45. Install the timing chain upper guide. Tighten the timing chain upper guide bolts to 89 inch lbs. (10 Nm).
  46.  
  47. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.

    Click image to see an enlarged view

    Fig. Measure the timing chain tensioner assembly from end to end

  48.  
  49. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure approximately 3 inches (72mm) (a) from end to end. A tensioner in the active state will measure 3 5 / 16 inches (85mm) (a) from end to end.

    Click image to see an enlarged view

    Fig. Compressing the timing chain tensioner

  50.  
  51. If the timing chain tensioner is not in the compressed state, perform the following steps:
    1. Remove the piston assembly from the body of the timing chain tensioner by pulling it out.
    2.  
    3. Install the J 45027-2 (2) into a vise.
    4.  
    5. Install the notch end of the piston assembly into the J 45027-2 (2).
    6.  
    7. Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
    8.  

  52.  
  53. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
  54.  
  55. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
  56.  
  57. At this point the tensioner should measure approximately 3 inches (72mm) (a) from end to end. If the tensioner does not read approximately 3 inches (72mm) (a) from end to end repeat steps 26.1 through 26.4.
  58.  
  59. Install the timing chain tensioner. Tighten the timing chain tensioner to 55 ft. lbs. (75 Nm).
  60.  
  61. Use a suitable tool with a rubber tip on the end. Feed the tool down through the camshaft drive chain to rest on the timing chain. Then give a sharp jolt diagonally downwards to release the tensioner.
  62.  
  63. Use a 24mm wrench to hold the camshaft. Tighten the NEW camshaft bolts to 63 ft. lbs. (85 Nm) plus 30°.
  64.  
  65. Install the camshaft cover.
  66.  
  67. Raise the vehicle.
  68.  
  69. Install the engine front cover.
  70.  
  71. Lower the vehicle.
  72.  

 
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