ION, L-Series, S-Series 1999-2005

Timing Chain Cover, Chain, Sprockets, & Seal 2

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Removal & Installation



2.4L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove the no. 1 cylinder spark plug.
  6.  
  7. Rotate the crankshaft in the engine rotational direction clockwise, until the no. 1 piston is at Top Dead Center (TDC) on the compression stroke.
  8.  
  9. Remove the camshaft cover.
  10.  
  11. Remove the engine front cover as follows:
    1. Remove the drive belt tensioner.
    2.  
    3. Remove the crankshaft balancer.
    4.  
    5. Remove the air cleaner assembly.
    6.  
    7. Remove the windshield washer solvent reservoir.
    8.  
    9. Install the engine support fixture.
    10.  
    11. Remove the engine mount to bracket bolts.
    12.  
    13. Remove the engine mount to side rail nuts.
    14.  
    15. Remove the engine mount from the engine compartment.
    16.  
    17. Remove the engine mount bracket to engine bolts.
    18.  
    19. Remove the engine mount bracket.
    20.  
    21. Remove the engine front cover to water pump bolt.
    22.  
    23. Raise and suitably support the vehicle.
    24.  
    25. Remove the engine front cover bolts.
    26.  
    27. Remove the engine front cover.
    28.  
    29. Remove and discard the engine front cover gasket.
    30.  

  12.  
  13. Remove the upper timing chain guide bolts and guide.
    NOTE
    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.

  14.  
  15. Remove the timing chain tensioner.

    Click image to see an enlarged view

    Fig. The timing chain tensioner must be removed to unload chain tension before the timing chain is removed-2.4L engine

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

    Click image to see an enlarged view

    Fig. Exhaust camshaft actuator assembly-2.4L engine



    Click image to see an enlarged view

    Fig. Remove the timing chain tensioner guide-2.4L engine

  20.  
  21. Remove the exhaust camshaft actuator from the camshaft and timing chain.
  22.  
  23. Remove the timing chain tensioner guide bolt and guide.
  24.  
  25. Remove the fixed timing chain guide access plug.
  26.  
  27. Remove the fixed timing chain guide bolts and guide.
  28.  
  29. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
  30.  
  31. Remove and discard the intake camshaft actuator bolt.
  32.  
  33. Remove the intake camshaft actuator, and the timing chain through the top of the cylinder head.
  34.  
  35. Remove the timing chain crankshaft sprocket.
  36.  
  37. If replacing the balance shaft timing chain and sprocket, perform the following:
    1. Remove the balance shaft drive chain tensioner bolts and tensioner.
    2.  
    3. Remove the adjustable balance shaft chain guide bolt and guide.
    4.  
    5. Remove the small balance shaft drive chain guide bolts and guide.
    6.  
    7. 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.



      Click image to see an enlarged view

      Fig. Remove the fixed timing chain guide access plug-2.4L engine



      Click image to see an enlarged view

      Fig. Remove the intake camshaft actuator, and the timing chain through the top of the cylinder head-2.4L engine



      Click image to see an enlarged view

      Fig. Remove the timing chain crankshaft sprocket-2.4L engine



      Click image to see an enlarged view

      Fig. Remove the balance shaft drive chain tensioner-2.4L engine



      Click image to see an enlarged view

      Fig. Remove the adjustable balance shaft chain guide-2.4L engine



      Click image to see an enlarged view

      Fig. Remove the small balance shaft drive chain guide-2.4L engine

    8.  
    9. Remove the balance shaft drive chain.
    10.  
    11. Remove the balance shaft drive sprocket .
    12.  

  38.  

To install:

  1. If replacing the balance shaft timing chain, perform the following:
    1. Install the balance shaft drive sprocket.
      NOTE
      If the balance shafts are not properly timed to the engine, the engine may vibrate or make noise.

    2.  
    3. Install the balance shaft drive chain with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and 1 is copper. Use the following steps in order to line up the links with the sprockets.
    4.  
    5. Place the copper link 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 chrome link in line with the timing mark on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket).
    8.  
    9. Place the chain on the water pump drive sprocket. The alignment is not critical.
    10.  
    11. Align the last chrome link with the timing mark on the exhaust side balance shaft drive sprocket.
    12.  
    13. Install the upper balance shaft drive chain guide and bolts. Tighten to 11 ft. lbs. (15 Nm).
    14.  
    15. Install the small balance shaft drive chain guide and bolts. Tighten to 11 ft. lbs. (15 Nm).
    16.  
    17. Install the adjustable balance shaft chain guide and bolt. Tighten to 89 in. lbs. (10 Nm).
    18.  

  2.  
  3. Reset the timing chain tensioner as follows:
    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.  
    5. Install the balance shaft drive chain tensioner and bolts. Tighten to 89 in. lbs. (10 Nm).
    6.  
    7. Remove the paper clip from the balance shaft drive chain tensioner.
    8.  

  4.  
  5. Ensure the intake camshaft notch is in the 5 o'clock position and the exhaust camshaft notch is in the 7 o'clock position. The number 1 piston should be at TDC, crankshaft key at 12 o'clock.
  6.  
  7. 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.
    NOTE
    There are 3 colored links on the timing chain. Two 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. Always use new actuator bolts.



    Click image to see an enlarged view

    Fig. Ensure the intake camshaft notch is in the 5 o'clock position and the exhaust camshaft notch is in the 7 o'clock position. The number 1 piston should be at TDC, crankshaft key at 12 o'clock-2.4L engine



    Click image to see an enlarged view

    Fig. 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-2.4L engine



    Click image to see an enlarged view

    Fig. Look for the timing chain link that is its own unique color. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link-2.4L engine

  8.  
  9. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link.
  10.  
  11. 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.
  12.  
  13. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
  14.  
  15. Hand tighten the new intake camshaft actuator bolt.
  16.  
  17. 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.
  18.  
  19. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
  20.  
  21. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten to 89 in. lbs. (10 Nm).
    NOTE
    Always install NEW actuator bolts.



    Click image to see an enlarged view

    Fig. 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-2.4L engine



    Click image to see an enlarged view

    Fig. 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-2.4L engine

  22.  
  23. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
  24.  
  25. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
  26.  
  27. 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.
  28.  
  29. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
  30.  
  31. 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. Install the fixed timing chain guide and bolts. Tighten to 106 in. lbs. (12 Nm).
  32.  
  33. Install the upper timing chain guide and bolts. Tighten to 89 in. lbs. (10 Nm).

    Click image to see an enlarged view

    Fig. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link-2.4L engine



    Click image to see an enlarged view

    Fig. 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-2.4L engine



    Click image to see an enlarged view

    Fig. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the steps in the procedure necessary to align the timing marks -2.4L engine

  34.  
  35. Reset the timing chain tensioner as follows:
    1. Remove the snap ring.
    2.  
    3. Remove the piston assembly from the body of the timing chain tensioner.
    4.  
    5. Remove the piston assembly from the body of the timing chain tensioner
    6.  
    7. Install the J 45027-2 into a vise.
    8.  
    9. Install the notch end of the piston assembly into the J 45027-2.
    10.  
    11. Using the J 45027-1 , turn the ratchet cylinder into the piston.
    12.  
    13. Reinstall the piston assembly into the body of the tensioner.
    14.  
    15. Install the snap ring.

      Click image to see an enlarged view

      Fig. Resetting the timing chain tensioner-2.4L engine



      Click image to see an enlarged view

      Fig. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt-2.4L engine

    16.  

  36.  
  37. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
  38.  
  39. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
    NOTE
    Ensure the timing chain tensioner seal is centered throughout the torque procedure to eliminate the possibility of an oil leak.

  40.  
  41. Install the timing chain tensioner assembly. Tighten to 55 ft. lbs. (75 Nm).
    NOTE
    The timing chain tensioner is released by compressing it 2 mm (0.079 in), 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.

  42.  
  43. Using a 23 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt.
  44.  
  45. Tighten the intake camshaft position actuator bolt to 22 ft. lbs. (30 Nm).), plus 100 degrees.
  46.  
  47. Using a 23 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten the exhaust camshaft position actuator bolt to 22 ft. lbs. (30 Nm).), plus 100 degrees.
  48.  
  49. Install the timing chain oiling nozzle. Tighten to 89 in. lbs. (10 Nm). Apply sealant compound GM P/N 12345382 (Canadian P/N 10953489) to the thread of the timing chain guide bolt access hole plug.
  50.  
  51. Install the timing chain guide bolt access hole plug. Tighten to 66 ft. lbs. (90 Nm).
  52.  
  53. Install the engine front cover as follows:
    1. Install a NEW engine front cover gasket to the dowel pins.
    2.  
    3. Install the engine front cover. Tighten the bolts to 18 ft. lbs. 925 Nm).
    4.  
    5. Lower the vehicle.
    6.  
    7. Install the engine front cover to water pump bolt. Tighten the bolt to 18 ft. lbs. 925 Nm).
    8.  
    9. Position the engine mount bracket to the engine. Place the long bolts in the forward and lower rear holes. Place t he short bolt in the upper rear hole.
    10.  
    11. Tighten the engine mount bracket bolts in the following sequence.:

      Upper rear
       
      Lower rear
       
      Forward. Tighten all bolts to 37 ft. lbs. (50 Nm).
       

    12.  
    13. Install the engine mount to the engine compartment.
    14.  
    15. Install the engine mount to side rail nuts. Tighten to 74 ft. lbs. (100 Nm).
    16.  
    17. Install the engine mount to bracket bolts.
    18.  
    19. Tighten the engine mount to bracket bolts in the following sequence:

      Middle
       
      Rear
       
      Front. Tighten all bolts to 37 ft. lbs. (50 Nm).
       

    20.  
    21. Remove the engine support fixture.
    22.  
    23. Install the windshield washer solvent reservoir.
    24.  
    25. Install the air cleaner assembly.
    26.  
    27. Install the crankshaft balancer.
    28.  
    29. Install the drive belt tensioner.
    30.  

  54.  
  55. Install the camshaft cover.
  56.  
  57. Install the no. 1 cylinder spark plug.
  58.  

 
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