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  • cutchant 08/19/10 10:26 pm PST



    Removal & Installation

    1.9 and 2.0



    1. Before servicing the vehicle, refer to the precautions section.

    2. Disconnect the negative battery cable.

    3. Remove the camshaft cover.

    4. Remove the engine front cover as follows:

    5. Remove the drive belt.

    6. Using harmonic balancer holder J 38122-A to prevent the crankshaft from rotating and remove the balancer bolt and discard

    7. Remove the crankshaft balancer.

    8. Remove the drive belt tensioner.

    9. Remove the idler pulley.

    10. Remove the engine front cover to water pump bolt.

    11. Remove the remaining engine front cover bolts.

    12. Remove the engine front cover.

    13. If the engine front cover gasket is damaged, remove the front engine mount.

    14. 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



    15. 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.

    16. Remove the timing chain tensioner.

    17. Remove the fixed timing chain guide access plug.

    18. Remove the fixed timing chain guide.



      Click image to see an enlarged view


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



    19. Remove the upper timing chain guide.

    20. 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



    21. Remove the exhaust camshaft sprocket bolt and discard.

    22. Remove the exhaust camshaft sprocket.

    23. Remove the timing chain tensioner guide.

    24. Remove the intake camshaft sprocket bolt and discard.

    25. Remove the intake camshaft sprocket.

    26. 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



    27. Remove the crankshaft sprocket.

    28. 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



    29. Remove the balance shaft drive chain tensioner.

    30. Remove the adjustable balance shaft chain guide.

    31. Remove the small balance shaft drive chain guide.

    32. 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.



    33. Remove the balance shaft drive chain.


    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. 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.

    3. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.

    4. 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).

    5. Place the chain (3) on the water pump drive sprocket (alignment is not critical).

    6. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.

    7. Install the small balance shaft chain guide. Tighten the balance shaft chain guide bolts to 89 inch lbs. (10 Nm).

    8. Install the adjustable balance shaft drive chain guide. Tighten the chain guide bolts to 89 inch lbs. (10 Nm).

    9. 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. Install the timing chain tensioner. Tighten the chain tensioner bolts to 89 inch lbs. (10 Nm).

    11. Remove the paper clip from the balance shaft drive chain tensioner.

    12. 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



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

    14. 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



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


      NOTE

      Always install NEW sprocket bolts.



    16. Hand tighten a NEW intake camshaft sprocket bolt.

    17. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark.

    18. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.

    19. 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



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

    21. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.


      NOTE

      Always install NEW sprocket bolts.



    22. Hand tighten the NEW exhaust camshaft sprocket bolt.

    23. Install the fixed timing chain guide and tighten the fixed timing chain bolts to 133 inch lbs. (15 Nm)

    24. 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).

    25. Install the timing chain upper guide. Tighten the timing chain upper guide bolts to 89 inch lbs. (10 Nm).

    26. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.

    27. 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



    28. 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. Install tensioner tool J 45027-2 into a vise.



    29. Install the notch end of the piston assembly into tensioner tool J 45027-2.

    30. Using tool J 45027-1, turn the ratchet cylinder into the piston.

    31. 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.

    32. 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.

    33. 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.

    34. Install the timing chain tensioner. Tighten the timing chain tensioner to 55 ft. lbs. (75 Nm).

    35. 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.

    36. 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.

    37. Install the camshaft cover.

    38. If removed install a new engine front cover gasket.

    39. Install the front engine mount bracket as follows:


      1. Install the intermediate bracket to the engine.

      2. 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.

      3. Tighten the intermediate bracket bolts to 74 ft. lbs. (100 Nm).



    40. Install the front engine mount as follows:


      1. Place the engine mount onto the midrail and hand start the nuts.

      2. 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.





    41. Hand start the engine mount to intermediate bracket bolts.

    42. Tighten the engine mount to intermediate bracket bolts, starting with the center bolt. Tighten the bolts to 37 ft. lbs. (50 Nm).

    43. Install the engine front cover.

    44. Install the engine front cover bolts. Tighten the engine front cover bolts to 18 ft. lbs. (25 Nm).

    45. Install the water pump bolt. Tighten the water pump bolt to 18 ft. lbs. (25 Nm).

    46. Install the idler pulley. Tighten the bolts to 18 ft. lbs. (25 Nm).

    47. Install the drive belt tensioner. Tighten the drive belt tensioner bolts to 33 ft. lbs. (45 Nm).

    48. Install the crankshaft balancer.

    49. Install a NEW crankshaft balancer bolt.

    50. 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

    51. Install the engine drive belt.

    52. Connect the negative battery cable.

    hope this helps

  • teage07 08/20/10 11:07 am PST

    Thank you so much for that answer... it really helped...

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