Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Sunfire and 2004 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

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

Fig 1: View Of Upper Balance Shaft Drive Chain Guide

Courtesy of GENERAL MOTORS CORP.

Install the upper balance shaft chain guide.
Tighten: Tighten the upper balance shaft chain guide bolts to 10 N.m (89 lb in).
Install the small balance shaft chain guide.

Fig 2: Exploded View Of Small Balance Shaft Drive Chain Guide
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Tighten the balance shaft chain guide bolts.
Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
Install the adjustable balance shaft drive chain guide.
Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).

Fig 3: View Of Adjustable Balance Shaft Chain Guide
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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.
Install the timing chain tensioner.

Fig 4: View Of Timing Chain Tensioner
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Tighten the chain tensioner bolts.
Tighten: Tighten the chain tensioner bolts to 10 N.m (89 lb in).
Remove the paper clip from the balance shaft drive chain tensioner.
Install the oil nozzle and bolt.

Fig 5: View Of Oil Nozzle & Bolt
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Tighten: Tighten the oil nozzle bolt to 10 N.m (89 lb in).
Install the crankshaft sprocket with timing mark at the 5 o'clock position.

Fig 6: View Of Crankshaft Sprocket Timing Mark
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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).

Fig 7: Locating Cylinder Block Bosses
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Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position.
Hand tighten a NEW intake camshaft sprocket bolt.
Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark.

Fig 8: Aligning Timing Chain Link & Intake Sprocket Timing Mark
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Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.
Install the timing chain tensioner guide through the opening in the top of the cylinder head.
Tighten: Tighten the timing chain tensioner guide bolt to 10 N.m (89 lb in).

Fig 9: View Of Timing Chain Tensioner Guide
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Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position.

Fig 10: Aligning Timing Chain Link & Exhaust Timing Mark
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Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.

Fig 11: Using 24 mm Wrench To Align Camshaft
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Hand tighten the NEW exhaust camshaft sprocket bolt.
Install the fixed timing chain guide.
Tighten: Tighten the fixed timing chain bolts to 10 N.m (89 lb in).

Fig 12: View Of Fixed Timing Chain Guide
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Verify that all the colored links are aligned with the appropriate exhaust(1), intake (2), and crankshaft marks(3).

Fig 13: Aligning Timing Marks
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Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) compound to thread and install the timing chain guide bolt access hole plug.
Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).

Fig 14: View Of Fixed Timing Chain Guide Access Plug
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Install the engine mount. Refer to Engine Mount Bracket Replacement .
Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.

Fig 15: Measuring Timing Chain Tensioner Assembly
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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 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
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 the J 45027-2 (2) into a vise.
3. Install the notch end of the piston assembly into the J 45027-2 (2).
4. Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
Fig 16: Compressing Timing Chain Tensioner
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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.

Fig 17: Measuring Timing Chain Tensioner Assembly

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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.
At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end repeat steps 16.1 and 16.4.
Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
Install the new timing chain tensioner assembly.
Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).

Fig 18: Identifying Timing Chain Tensioner
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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.
Use a 24 mm wrench to hold the camshaft.
Tighten: Tighten the NEW camshaft bolts to 85 N.m (63 lb ft) plus 30 degrees.

Fig 19: Holding Camshaft Stationary With Wrench On Hex Casting On Camshaft
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Install the camshaft cover. Refer to Camshaft Cover Replacement .
Raise the vehicle.
Install the engine front cover. Refer to Engine Front Cover Replacement .
Lower the vehicle.
Connect negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.