ION 2006-2007

Timing Chain Cover, Chain, Sprockets, & Seal 1

Print

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the camshaft cover.
  6.  
  7. Remove the engine front cover as follows:
  8.  
  9. Remove the drive belt.
  10.  
  11. Using harmonic balancer holder J 38122-A to prevent the crankshaft from rotating and remove the balancer bolt and discard
  12.  
  13. Remove the crankshaft balancer.
  14.  
  15. Remove the drive belt tensioner.
  16.  
  17. Remove the idler pulley.
  18.  
  19. Remove the engine front cover to water pump bolt.
  20.  
  21. Remove the remaining engine front cover bolts.
  22.  
  23. Remove the engine front cover.
  24.  
  25. If the engine front cover gasket is damaged, remove the front engine mount.
  26.  
  27. Remove the front engine mount bracket
    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. 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)-2.0L engine

  28.  
  29. 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). Remove the spark plugs. This will ease the rotation effort.
  30.  
  31. Remove the timing chain tensioner.
  32.  
  33. Remove the fixed timing chain guide access plug.
  34.  
  35. Remove the fixed timing chain guide.

    Click image to see an enlarged view

    Fig. Remove the fixed timing chain guide-2.0L engine

  36.  
  37. Remove the upper timing chain guide.
  38.  
  39. Use a 24 mm wrench to hold the camshafts from turning.

    Click image to see an enlarged view

    Fig. Use a 24 mm wrench to hold the camshafts from turning-2.0L engine

  40.  
  41. Remove the exhaust camshaft sprocket bolt and discard.
  42.  
  43. Remove the exhaust camshaft sprocket.
  44.  
  45. Remove the timing chain tensioner guide.
  46.  
  47. Remove the intake camshaft sprocket bolt and discard.
  48.  
  49. Remove the intake camshaft sprocket.
  50.  
  51. Remove the timing chain through the top of the cylinder head.

    Click image to see an enlarged view

    Fig. Remove the timing chain through the top of the cylinder head-2.0L engine

  52.  
  53. Remove the crankshaft sprocket.
  54.  
  55. Remove the oil nozzle and bolt.

    Click image to see an enlarged view

    Fig. Remove the timing chain through the top of the cylinder head-2.0L engine



    Click image to see an enlarged view

    Fig. Remove the balance shaft drive chain tensioner-2.0L engine

  56.  
  57. Remove the balance shaft drive chain tensioner.
  58.  
  59. Remove the adjustable balance shaft chain guide.
  60.  
  61. Remove the small balance shaft drive chain guide.
  62.  
  63. 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.

  64.  
  65. Remove the balance shaft drive chain.
  66.  

To install:


NOTE
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 133 inch lbs. (15 Nm).

    Click image to see an enlarged view

    Fig. Refer to the text for the proper timing chain routing for installation-2.0L engine

  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.
  4.  
  5. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
  6.  
  7. 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).
  8.  
  9. Place the chain (3) on the water pump drive sprocket (alignment is not critical).
  10.  
  11. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.
  12.  
  13. Install the small balance shaft chain guide. Tighten the balance shaft chain guide bolts to 89 inch lbs. (10 Nm).
  14.  
  15. Install the adjustable balance shaft drive chain guide. Tighten the chain guide bolts to 89 inch lbs. (10 Nm).
  16.  
  17. 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.
  18.  
  19. Install the timing chain tensioner. Tighten the chain tensioner bolts to 89 inch lbs. (10 Nm).
  20.  
  21. Remove the paper clip from the balance shaft drive chain tensioner.
  22.  
  23. 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-2.0L engine

  24.  
  25. Install the crankshaft sprocket with timing mark at the 5 o'clock position.
  26.  
  27. 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 and 2).

    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 and 2)-2.0L engine



    Click image to see an enlarged view

    Fig. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position-2.0L engine

  28.  
  29. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position.
    NOTE
    Always install NEW sprocket bolts.

  30.  
  31. Hand tighten a NEW intake camshaft sprocket bolt.
  32.  
  33. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark.
  34.  
  35. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.
  36.  
  37. 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-2.0L engine

  38.  
  39. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position.
  40.  
  41. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.
    NOTE
    Always install NEW sprocket bolts.

  42.  
  43. Hand tighten the NEW exhaust camshaft sprocket bolt.
  44.  
  45. Install the fixed timing chain guide and tighten the fixed timing chain bolts to 133 inch lbs. (15 Nm)
  46.  
  47. Apply sealant, GM P/N 12378521 to the threads and install the timing chain guide bolt access hole plug. Tighten the chain guide plug to 59 ft. lbs. (90 Nm).
  48.  
  49. Install the timing chain upper guide. Tighten the timing chain upper guide bolts to 89 inch lbs. (10 Nm).
  50.  
  51. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
  52.  
  53. 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 2.83 inch (72 mm) (a) from end to end. A tensioner in the active state will measure 3.35 inch (85 mm) from end to end.

    Click image to see an enlarged view

    Fig. Measure the timing chain tensioner assembly from end to end. Refer to the text for measurement specifications-2.0L engine

  54.  
  55. 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 tensioner tool J 45027-2 into a vise.
    4.  

  56.  
  57. Install the notch end of the piston assembly into tensioner tool J 45027-2.
  58.  
  59. Using tool J 45027-1, turn the ratchet cylinder into the piston.
  60.  
  61. 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.
  62.  
  63. 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.
  64.  
  65. At this point the tensioner should measure approximately 2.83 inch (72 mm) from end to end. If the tensioner does not read 2.83 inch (72 mm) from end to end repeat the compression steps.
  66.  
  67. Install the timing chain tensioner. Tighten the timing chain tensioner to 55 ft. lbs. (75 Nm).
  68.  
  69. 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.
  70.  
  71. Use a 24 mm wrench to hold the camshaft. Tighten the NEW camshaft bolts to 63 ft. Lbs. (85 Nm) plus an additional 30 degrees.
  72.  
  73. Install the camshaft cover.
  74.  
  75. If removed install a new engine front cover gasket.
  76.  
  77. Install the front engine mount bracket as follows:
    1. Install the intermediate bracket to the engine.
    2.  
    3. Hand tighten the engine mount intermediate bracket bolts. Position the long bolts in the forward and front lower holes and the short bolt in the rear upper hole.
    4.  
    5. Tighten the intermediate bracket bolts to 74 ft. lbs. (100 Nm).
    6.  

  78.  
  79. Install the front engine mount as follows:
    1. Place the engine mount onto the midrail and hand start the nuts.
    2.  
    3. Tighten the engine mount to midrail nuts to 74 ft. lbs. (100 Nm).
      NOTE
      The engine mount to intermediate bracket bolts must be hand started. Do not pry the engine mount to align the holes.

    4.  

  80.  
  81. Hand start the engine mount to intermediate bracket bolts.
  82.  
  83. Tighten the engine mount to intermediate bracket bolts, starting with the center bolt. Tighten the bolts to 37 ft. lbs. (50 Nm).
  84.  
  85. Install the engine front cover.
  86.  
  87. Install the engine front cover bolts. Tighten the engine front cover bolts to 18 ft. lbs. (25 Nm).
  88.  
  89. Install the water pump bolt. Tighten the water pump bolt to 18 ft. lbs. (25 Nm).
  90.  
  91. Install the idler pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).
  92.  
  93. Install the drive belt tensioner. Tighten the drive belt tensioner bolts to 33 ft. lbs. (45 Nm).
  94.  
  95. Install the crankshaft balancer.
  96.  
  97. Install a NEW crankshaft balancer bolt.
  98.  
  99. Using tool J 38122-A to prevent the crankshaft from rotating, install a new balancer bolt and tighten to 74 ft. lbs. (100 Nm) plus an additional 75 degrees
  100.  
  101. Install the engine drive belt.
  102.  
  103. Connect the negative battery cable.
  104.  

2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accelerator cable from the throttle body and bracket
     
    Accelerator bracket bolts and the bracket
     
    Positive Crankcase Ventilation (PCV) hose
     
    Fuel line bracket
     
    Ignition Coil Module (ICM) connector
     
    ICM screws and the ICM
     
    Ignition coil housing bolts and the housing
     
    Ground strap stud from the camshaft cover
     
    Ground strap
     
    Camshaft cover bolts
     
    Camshaft cover
     
    Accessory drive belt
     
    Using harmonic balancer holder J 38122-A to prevent the crankshaft from rotating and remove the balancer bolt and discard
     
    Crankshaft balancer
     
    Belt tensioner
     

  6.  
  7. Remove the front engine mount as follows:
    1. Support the engine with a jack and a piece of wood.
    2.  
    3. Remove the mount-to-intermediate bracket bolts
    4.  
    5. Remove the mount-to-midrail nuts
    6.  
    7. Remove the mount.
      NOTE
      The timing chain has 2 matching colored links and 1 unique colored link.



      Front cover bolts and the 13mm bolt under the water pump
       
      Front cover
       

    8.  

  8.  
  9. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link at the 5 o- clock position.
  10.  
  11. Make sure the timing chain to the intake camshaft sprocket alignment copper link to the -INT- diamond timing mark on the camshaft sprocket.
  12.  
  13. Make sure the -EXH- triangle on the exhaust camshaft sprocket is aligned with the colored link.
  14.  
  15. Remove or disconnect the following:
    NOTE
    To make it easier to remove the balance shaft chain, get all the slack in the chain between the crankshaft and the water pump sprockets.



    Timing chain tensioner
     
    Fixed timing chain guide access plug and the guide
     
    Upper timing chain guide
     
    Exhaust camshaft sprocket
     
    Timing chain tensioner guide
     
    Intake camshaft sprocket
     
    Timing chain through the top of the cylinder head
     
    Timing chain sprocket from the crankshaft
     
    Balance shaft drive chain tensioner
     
    Adjustable timing 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 timing chain through the top of the cylinder head-ION with 2.2L engine

     

  16.  

To install:


NOTE
If the balance shafts are not properly aligned engine noise will occur.

  1. Install or connect the following:

    Upper balance shaft chain guide and tighten the bolts to 89 inch lbs. (10 Nm)
     

  2.  
  3. Install the balance shaft chain with the colored links lined up on the marks on the balance shaft drive sprockets and crankshaft sprocket. Use the following to align the links with the sprockets while referring to the accompanying illustration for link location:

    Click image to see an enlarged view

    Fig. Install the balance shaft chain with the colored links lined up on the marks on the balance shaft drive sprockets and crankshaft sprocket -ION with 2.2L engine

    1. Place the chain so that the copper colored and chrome links can be clearly seen
    2.  
    3. Place link 1 (see illustration) so that it aligns with the timing mark on the intake side balance shaft sprocket.
    4.  
    5. Working in a clockwise direction around the chain, place the link 2 (see illustration) in line with the timing mark on the crankshaft sprocket, this will be approximately at the 5 o-clock position.
    6.  
    7. Place link 3 (see illustration) on the water pump sprocket (alignment is not critical).
    8.  
    9. Align link 4 (see illustration) with the timing mark on the exhaust side balance shaft sprocket.
    10.  
    11. Install the small balance shaft chain guide and tighten the bolts to 89 inch lbs. (10 Nm).
    12.  
    13. Install the adjustable balance shaft drive chain guide and tighten the bolts to 89 inch lbs. (10 Nm).
    14.  
    15. 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 the hole in the plunger.
    16.  
    17. Install the timing chain tensioner and tighten the bolts to 89 inch lbs. (10 Nm).
    18.  
    19. Remove the clip from the balance shaft tensioner.
    20.  

  4.  
  5. Inspect the chain guides for wear and damage. Replace the guides if wear exceeds 0.045 inch (1.12mm). Inspect the timing chain shoe. Replace the shoe if wear exceeds 0.045 inch (1.12mm).
  6.  
  7. Install or connect the following:

    Timing chain sprocket to the crankshaft. Rotate the crankshaft so that the mark on the sprocket is at the 5 o-clock position.
     

  8.  
  9. Lower the timing chain through the opening in the cylinder head. make sure the chain goes around both sides of the cylinder block bosses (see illustration).

    Click image to see an enlarged view

    Fig. Lower the timing chain through the opening in the cylinder head. make sure the chain goes around both sides of the cylinder block bosses-ION with 2.2L engine



    Intake camshaft sprocket with the -INT- diamond at the 2 o-clock position and hand-tighten a new intake camshaft sprocket bolt
     
    Timing chain around the crankshaft sprocket and align the silver link to the timing mark
     
    Timing chain to the intake camshaft sprocket alignment copper link to the -INT- diamond timing mark on the camshaft sprocket
     
    Timing chain tensioner guide and torque the bolt to 89 inch lbs. (10 Nm)
     
    Exhaust camshaft sprocket loosely on the camshaft with the timing mark on the sprocket aligned with the silver link (3) on the chain at the 10 o-clock position and hand-tighten the new bolt at this time

    Click image to see an enlarged view

    Fig. Align the timing mark on the exhaust camshaft sprocket with the silver link (3) on the chain-ION with 2.2L engine

     

  10.  
  11. Align the camshaft sprocket to camshaft and tighten the bolt using the following procedure:
    1. Make certain that the sprocket timing mark is at the 5 o-clock position.
    2.  
    3. Rotate the intake camshaft using a 24mm wrench on flats of the camshaft until the sprocket to camshaft alignment notch seats.
    4.  
    5. When seated properly hand-tighten the bolt.
    6.  
    7. Rotate the exhaust camshaft using a 24mm wrench on flats of the camshaft until the sprocket to camshaft alignment notch seats.
    8.  
    9. When seated properly hand-tighten the bolt.
    10.  

  12.  
  13. Verify that all colored links are aligned with the proper marks on the camshaft and crankshaft sprockets.
  14.  
  15. Install or connect the following:

    Fixed timing chain guide and tighten the bolt to 89 inch lbs. (10 Nm)
     
    Apply Saturn compound 21485277 to the fixed timing chain guide bolt access plug threads, install the bolt and torque it to 30 ft. lbs. (40 Nm)
     
    Upper timing chain guide and torque the bolts to 89 inch lbs. (10 Nm)
     

  16.  
  17. Inspect the timing chain tensioner. If the tensioner O-ring or washer is damaged the tensioner must be replaced.
  18.  
  19. If replacing the tensioner, measure the tensioner assembly from end-to-end. A new tensioner should be in the fully compressed non-active state. A tensioner in the non-active state should measure 2.83 inches (72mm) from end-to-end. The tensioner in the active state will measure 3.35 inches (85mm) from end-to-end.
  20.  
  21. If the tensioner is not in the compressed state, perform the following steps:
    1. Pull the piston assembly from the tensioner body.
    2.  
    3. Install tensioner tool J 45027-2 into a vise.
    4.  
    5. Install the notch end of the piston assembly into J 45027-2.
    6.  
    7. Using tool J 45027-1, turn the ratchet cylinder into the pump.
    8.  
    9. Inspect the bore of the tensioner body for damage or dirt. If any damage is present, replace the tensioner.
    10.  
    11. Install the compressed piston assembly back into the tensioner body until it bottoms out in the bore. Do not compress the piston against the bottom of the bore. If the piston is compressed in the bore it will activate the tensioner and the piston will have to be reset.
    12.  
    13. Check that the tensioner measures 2.83 inches (72mm) from end-to-end. If this measurement is incorrect, reset the piston.

      Click image to see an enlarged view

      Fig. Resetting the timing chain tensioner piston-ION with 2.2L engine

    14.  
    15. Install the tensioner assembly and tighten to 55 ft. lbs. (75 Nm)
    16.  
    17. Using 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. Give a sharp jolt diagonally downwards to release the tensioner.
    18.  

  22.  
  23. Install or connect the following:

    Intake and exhaust camshaft sprocket bolts and torque them to 63 ft. lbs. (85 Nm) plus 30 degrees. Use a 24mm wrench as a back-up when tightening the bolts.
     
    Sealing ring and tensioner assembly and torque the tensioner bolts to 44 ft. lbs. (60 Nm)
     
    Camshaft cover
     
    Camshaft cover bolts and tighten to 89 inch lbs. (10 Nm)
     
    Ground strap
     
    Ground strap stud to the camshaft cover and tighten to 89 inch lbs. (10 Nm)
     
    Ignition coil housing and tighten the bolts to 89 inch lbs. (10 Nm)
     
    ICM and tighten the screws to 13 inch lbs. (1.5 Nm)
     
    ICM connector
     
    Fuel line bracket
     
    PCV hose
     
    Accelerator bracket and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Accelerator cable to the throttle body and bracket
     
    Front cover gasket
     

  24.  
  25. Install the front engine mount as follows:
    1. Install the mount.
    2.  
    3. Install the mount-to-midrail nuts and torque them to 74 ft. lbs. (100 Nm).
    4.  
    5. Install the mount-to-intermediate bracket bolts and torque to 37 ft. lbs. (50 Nm). Never pry the mount to align the holes, raise or lower the jack for alignment purposes.
    6.  
    7. Remove the jack.
    8.  

  26.  
  27. Install or connect the following:

    Front cover and torque the bolts to 18 ft. lbs. (25 Nm) and the water pump bolt to 15 ft. lbs. (20 Nm)
     
    Drive belt tensioner and torque the fasteners to 33 ft. lbs. (45 Nm)
     
    Crankshaft balancer
     
    Balancer bolt and using tool J 38122-A to prevent the crankshaft from rotating, install a new balancer bolt and tighten to 74 ft. lbs. (100 Nm) plus an additional 75 degrees
     
    Drive belt
     
    Negative battery cable
     

  28.  
  29. Fill the engine with clean oil.
  30.  
  31. Start the vehicle and check for leaks, repair if necessary.

    Click image to see an enlarged view

    Fig. Align the copper link on the timing chain with the INT diamond timing mark-ION with 2.2L engine



    Click image to see an enlarged view

    Fig. Make sure the -EXH- triangle on the exhaust camshaft sprocket is aligned with the colored link-ION with 2.2L engine



    Click image to see an enlarged view

    Fig. Route the timing chain around the crankshaft sprocket and align the silver link to the timing mark (5 o-clock position)-ION with 2.2L engines

  32.  

 
label.common.footer.alt.autozoneLogo