Removal & Installation2.2L Engine
Before servicing the vehicle, refer to the precautions section.
Drain the cooling system.
Drain the engine oil.
Properly relieve the fuel system pressure.
Remove or disconnect the following:
Negative battery cable
Intake Air Temperature (IAT) sensor connection
Air cleaner assembly
Ignition module assembly
Electronic Control Module (ECM) connections
Oil dipstick tube bolt
Throttle body electrical connection
Electrical connector from the fuel injector harness and attachment at the bottom of the intake manifold
Electrical connector at the purge solenoid and Manifold Absolute Pressure (MAP) sensor
Vacuum hose at the brake booster
Coolant pipe bracket bolts from the cylinder head
De-gas hose clamp from the cylinder head and fuel rail and position aside
Ground strap from the rear cam cover
Fuel rail bracket from the cam cover
Position the No. 1 piston 60 degrees Before Top dead center (TDC) using a 24mm wrench to rotate the camshafts in a clockwise motion and make sure the diamond shaped hole on the intake sprocket is at the 12 O-clock position.
Remove the timing chain tensioner to unload chain tension before removing the timing chain.
Fig. Position the No. 1 piston 60 degrees Before Top dead center (TDC) using a 24mm wrench to rotate the camshafts in a clockwise motion and make sure the diamond shaped hole on the intake sprocket is at the 12 O-clock position-2.2L engine
Fixed timing chain guide access plug
Upper fixed guide bolt using a magnetic socket
Install a three bar engine support fixture.
Right hand engine mount
Right hand mount bracket
Right wheel splash shield
Install a 1 x 2 x 4 inch block of wood between the oil pan and cradle
Drive belt tensioner assembly
Install crankshaft pullet holder J38122A..
Crankshaft balancer bolt and pulley
Front cover bolts
Lower water pump bolt
Front cover and gasket
Lower fixed guide
Upper radiator hose from the cylinder head
Exhaust manifold pipe nuts
Front and rear Oxygen (O
S) sensor electrical connector
Down pipe-to-intermediate pipe nuts Down pipe
Exhaust camshaft sprocket bolts while holding the camshaft with a 24mm wrench and discard the camshaft sprocket bolts
Adjustable guide through the top of the cylinder head
Intake camshaft sprocket bolts while holding the camshaft with a 24mm wrench and discard the camshaft sprocket bolts
Timing chain assembly
Timing drive sprocket from the crankshaft
Fig. Remove the timing chain through the top of the cylinder head-2.2L engine
Set the crankshaft to 60 degrees Before Top Dead Center (BTDC) to prevent contact between the pistons and valves.
Install or connect the following:
Position the exhaust camshaft with the offset slot in the 2 o-clock position and the intake camshaft with the offset slot in the 11 o-clock position.
Make certain that all timing marks and colored links are aligned properly before proceeding to the next step. If the timing chain is not aligned properly, severe engine damage may occur.
Fig. Align the copper link on the timing chain with the INT diamond timing mark
Fig. Route the timing chain around the crankshaft sprocket and align the silver link to the timing mark (5 o-clock position)-2.2L engines
Timing chain around the intake camshaft sprocket with the copper link aligned with the
diamond timing mark
Sprocket to the camshaft and align it with the offset slot
New camshaft sprocket bolt but do not tighten
Timing chain around the crankshaft sprocket and align the silver link to the timing mark
Adjustable timing chain guide through the opening on top of the cylinder head and torque the bolt to 89 inch lbs. (10 Nm)
Timing chain around the exhaust camshaft sprocket with the silver link aligned with the offset slot. Install but do not tighten a new sprocket bolt
Torque the intake and exhaust camshaft bolts to 63 ft. lbs. (85 Nm) plus a 30 degree turn.
Install or connect the following:
Fixed timing guide and torque the bolt to 89 inch lbs. (10 Nm)
Fixed timing guide bolt access plug after applying Loctite®to the threads and torque it to 30 ft. lbs. (40 Nm)
Timing chain tensioner and torque the bolts 55 ft. lbs. (75 Nm)
Tap the top of the timing chain between the camshaft sprockets to engage the tensioner.
Upper timing chain guide and torque the bolts to 89 inch lbs. (10 Nm)
Front cover with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm)
Water pump bolt and torque it to 18 ft. lbs. (25 Nm)
Crankshaft damper and torque the bolt to 74 ft. lbs. (100 Nm) plus 75 degrees
Drive belt tensioner and torque the bolts to 30 ft. lbs. (40 Nm)
Exhaust manifold pipe to the manifold and tighten the nuts to 22 ft. lbs. (30 Nm).
Oil dipstick tube bolt to 89 inch lbs. (10 Nm).
Engine mount bracket and torque the bolts to 66 ft. lbs. (90 Nm)
Engine mount to body nuts to 81 ft. lbs. (110 Nm)
Engine mount to the bracket and torque the bolts to 41 ft. lbs. (55 Nm)
Remaining components in the reverse order of removal.
Fill the engine with clean oil.
Fill the cooling system.
Prime the fuel system by cycling the ignition
for 5 seconds and
for 10 seconds a few times without cranking the engine.
Start the engine, check for leaks, and repair if necessary