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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1814 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Timing Chain, Sprockets, and/or Tensioner Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Removing/Installing Timing Chain Drive Sprocket
    GM897597Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  1. Install the timing chain oiler nozzle and the bolt, then tighten.

    Tighten:  Tighten the timing chain oil nozzle bolt to 10 N.m (89 lb in).

  2. Install the timing chain drive sprocket to the crankshaft.
    3. Fig 2: Setting Mark On The Timing Chain Drive Sprocket At 5 O'clock Position
    GM895036Courtesy of GENERAL MOTORS CORP.
    NOTE: Set crankshaft to 60 degrees before top-dead center or after TDC to prevent valve to piston contact.
  3. Using the dampener, rotate the crank so that the mark on the timing chain drive sprocket is at 5 o'clock position.
  4. Set the crankshaft to 60 degrees before the top dead center.
    5. Fig 3: Positioning Exhaust Camshaft
    GM895039Courtesy of GENERAL MOTORS CORP.
  5. Position the exhaust camshaft with the offset slot to 2 o'clock position.
    6. Fig 4: Positioning Intake Camshaft
    GM895009Courtesy of GENERAL MOTORS CORP.
  6. Position intake camshaft with offset slot to 11 o'clock position.
  7. Assemble the chain to the intake camshaft sprocket aligning the upper link to the INT diamond timing mark on the camshaft sprocket.
    8. Fig 5: Rotating Assembly 90 Degrees To Allow The Chain To Fall Between The Cylinder Block Bosses
    GM895010Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: When lowering the timing chain into the cylinder head, rotate the assembly 90 degrees to allow the chain to fall between the cylinder block bosses, then rotate the assembly back so that the camshaft sprocket is facing forward.
  8. Lower the assembly through chain housing opening on top of the cylinder head. Use care to make sure that the chain goes around both sides of the cylinder block bosses.
    9. Fig 6: Routing The Timing Chain Around The Crankshaft Sprocket
    GM947974Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: The crankshaft sprocket timing mark will be at approximately the 5 o'clock position.
  9. Route the chain around the crankshaft sprocket and align the silver link to the timing mark.
    10. Fig 7: Positioning Intake Camshaft
    GM895009Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are not reusable, it is a torque-to-yield (TTY) bolt, and must be discarded to prevent premature failure.
  10. Install the intake camshaft sprocket with the chain in proper position to the camshaft. Rotate the intake camshaft using a 24 mm wrench on the flats on the camshaft until the camshaft aligns with the sprocket.
  11. Install the new intake camshaft sprocket bolt and finger tighten.
    12. Fig 8: Timing Chain Adjustable Guide And Bolt
    GM894967Courtesy of GENERAL MOTORS CORP.
    NOTE: Excess slack in the chain must be kept to the chain tensioner side (movable guide) of the cylinder block when installing the timing chain or the camshaft sprockets will not be correctly timed to the crankshaft sprocket.
    IMPORTANT: Make sure the crankshaft marks and the camshaft marks aligns with the colored links.
  12. Install the adjustable timing chain guide through the opening at the top of the cylinder head and install the chain guide bolt.

    Tighten:  Tighten the timing chain guide (adjustable) bolt to 10 N.m (89 lb in).

    13. Fig 9: Removing/Installing Exhaust Camshaft Sprocket
    GM894960Courtesy of GENERAL MOTORS CORP.
  13. Install the exhaust camshaft sprocket loosely on the exhaust camshaft with the timing mark on the sprocket aligned with the silver link.
  14. Install new camshaft sprocket bolt loosely.
    15. Fig 10: Using 24 mm Wrench To Hold/Rotate Camshaft
    GM895042Courtesy of GENERAL MOTORS CORP.
  15. Align the camshaft sprocket with the chain in proper position to the camshaft. Rotate the exhaust clockwise using a 24 mm wrench on the flats on the camshaft until the camshaft aligns with the sprocket.
    16. Fig 11: Verifying All Colored Timing Chain Links Are Aligned With Crankshaft & Camshaft Marks
    GM947947Courtesy of GENERAL MOTORS CORP.
  16. Verify that all the colored links are aligned with the appropriate intake (1), crankshaft sprocket (2), and (3) exhaust marks.
  17. Verify the crankshaft sprocket timing mark is at 5 o'clock.
  18. If marks are not correct, you must repeat the timing procedure.
    19. Fig 12: Removing/Installing Fixed Timing Chain Guide
    GM894969Courtesy of GENERAL MOTORS CORP.
  19. Install the fixed timing chain guide and bolts.

    Tighten:  Tighten the timing chain fixed bolts to 15 N.m (133 lb in).

    20. Fig 13: Fixed Timing Chain Guide Access Plug
    GM894968Courtesy of GENERAL MOTORS CORP.
  20. Apply the thread sealant to the thread. Refer to Sealers, Adhesives, and Lubricants  for the correct part number. Install fixed guide bolt access hole plug.

    Tighten:  Tighten the timing chain bolt access hole plug to 40 N.m (30 lb ft).

    21. Fig 14: Using 24 mm Wrench To Hold/Rotate Camshaft
    GM895042Courtesy of GENERAL MOTORS CORP.
    NOTE: Use a 24 mm wrench to support the camshaft while applying torque to camshaft sprocket bolt. Do not torque camshaft bolts against timing chain, as it may damage the timing chain.
  21. Tighten intake and exhaust camshaft sprocket bolts while holding camshaft with 24 mm wrench.

    Tighten:  Tighten the camshaft sprocket bolts to 85 N.m (63 lb ft) + 30 degrees

    22. Fig 15: Inspecting Timing Chain Tensioner
    GM946995Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: 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) (1) from end to end. A tensioner in the active state will measure 85 mm (3.53 in) from end to end.
  22. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
    23. Fig 16: Compressing Timing Chain Tensioner
    GM797246Courtesy of GENERAL MOTORS CORP.
  23. Measure the timing chain tensioner assembly from end-to-end.
  24. 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 J45027-2 (2) into a vise.
    3. Install the notch end of the piston assembly into the J45027-2 (2).
  25. Using J45027-1 (1), turn the ratchet cylinder into the piston.
    26. Fig 17: Inspecting Timing Chain Tensioner
    GM946995Courtesy of GENERAL MOTORS CORP.
  26. Inspect the bore of the tensioner body for dirt, debris and damage. If any damage appears, replace the tensioner. Clean dirt of debris out with a lint free cloth.
  27. 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.
  28. At this point, the tensioner should measure approximately 72 mm (2.83 in) (1) from end-to-end. If the tensioner does not read 72 mm (2.83 in) (1) from end to end repeat step 24
    29. Fig 18: Removing/Installing Timing Chain Tensioner Assembly
    GM894951Courtesy of GENERAL MOTORS CORP.
  29. Ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
  30. Install the new timing chain tensioner assembly bolt and tighten.

    Tighten:  Tighten the timing chain tensioner assembly bolt to 75 N.m (55 lb ft).

  31. 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.
    32. Fig 19: Removing/Installing Upper Timing Chain Guide
    GM894944Courtesy of GENERAL MOTORS CORP.
  32. Install the upper timing chain guide and bolts.

    Tighten:  Tighten the timing chain guide (upper) bolts to 10 N.m (89 lb in).

    33. Fig 20: Removing/Installing Front Cover Assembly
    GM895054Courtesy of GENERAL MOTORS CORP.
  33. Raise the vehicle if necessary.
  34. Install the new front cover gasket.
  35. Install the front cover assembly.
  36. Install the front cover assembly bolts.

    Tighten:  Tighten the front cover-to-block bolts to 25 N.m (18 lb ft).

  37. Install the front cover water pump bolt.

    Tighten:  Tighten the water pump bolts to 25 N.m (18 lb ft).

    38. Fig 21: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
    GM895194Courtesy of GENERAL MOTORS CORP.
  38. Lubricate the front seal and the sealing surface of the pulley with the clean motor oil.
  39. Install the balancer pulley onto the crankshaft indexing keyway. Use care to properly align the flats on the balancer pulley with the flats on the oil pump drive in the front cover assembly.
  40. Install the crankshaft damper pulley.
    41. Fig 22: Removing & Installing Damper Assembly
    GM895197Courtesy of GENERAL MOTORS CORP.
  41. Install the new crankshaft balancer pulley bolt with the washer assembly.
    42. Fig 23: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
    GM895194Courtesy of GENERAL MOTORS CORP.
  42. Install the J 38122-A  . See Special Tools .

    Tighten:  Tighten the crankshaft pulley bolt to 100 N.m (74 lb ft) + 75 degrees.

    43. Fig 24: Depressing Tensioner Arm
    GM896375Courtesy of GENERAL MOTORS CORP.
  43. Install the accessory drive belt tensioner.

    Tighten:  Tighten the drive belt tensioner bolts to 45 N.m (33 lb ft).

  44. Route belt around the alternator and the A/C compressor.
  45. Install the J 39914  onto the tensioner and unload spring tension from the tensioner while positioning the belt. See Special Tools .
  46. Release the tensioner and remove the tool.
    47. Fig 25: Removing/Installing Right Hand Engine Mount Bracket
    GM928024Courtesy of GENERAL MOTORS CORP.
  47. Install the right hand engine bracket and bolts.

    Tighten:  Tighten the engine mount bracket-to-engine bolts to 110 N.m (81 lb ft).

    48. Fig 26: View Of RH Engine Mount
    GM928650Courtesy of GENERAL MOTORS CORP.
  48. Install the right hand engine mount shims.
  49. Install the right hand engine mount onto the body side rail studs.
  50. Install the right hand engine mount-to-body nuts.

    Tighten:  Tighten the engine mount-to-body nuts to 110 N.m (81 lb ft).

  51. Install the right-hand engine mount-to-engine mount bracket bolts.

    Tighten:  Tighten the engine mount-to-engine mount bracket bolts to 50 N.m (37 lb ft).

  52. Remove the SA9105E  . See Special Tools .
  53. Install the right engine inner splash shield.
  54. Install the right wheel and hand-tighten the wheel nuts.
  55. Tighten the wheel nuts.

    Tighten:  Tighten the wheel nuts to 125 N.m (92 lb ft).

    56. Fig 27: Removing/Installing Cam Cover Assembly
    GM894940Courtesy of GENERAL MOTORS CORP.
  56. Visually inspect the camshaft cover gasket for signs of leakage. The camshaft cover gasket is reusable if not damaged.
  57. Assemble the camshaft cover and gasket using care to make sure that gasket is located in retaining groove on camshaft cover.
  58. Install the cover on cylinder head and hand-tighten the bolts.

    Tighten:  Tighten the camshaft cover bolts to 10 N.m (89 lb in).

    59. Fig 28: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
  59. Reposition fuel line assembly.
    60. NOTE: An open-end wrench must be used to support the fuel line to rail connection during loosening/tightening to avoid damaging the fuel rail assembly.
  60. Install the transfer line fitting at fuel to fuel rail.

    Tighten:  Tighten the transfer line fitting-to-fuel rail to 10 N.m (89 lb in).

    61. Fig 29: View Of Fuel Feed Pipe Fastener
    GM854304Courtesy of GENERAL MOTORS CORP.
  61. Connect the fuel rail bracket and bolt to the cylinder head.

    Tighten:  Tighten the fuel line bracket bolt to 10 N.m (89 lb in).

    62. Fig 30: Disconnecting/Connecting Ground Strap On The Camshaft Cover Assembly
    GM895199Courtesy of GENERAL MOTORS CORP.
  62. Connect the ground strap to the camshaft cover assembly.

    Tighten:  Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).

  63. Connect the degas hose and attach to the fuel rail.
  64. Connect the coolant pipe bracket bolts to the cylinder head.

    Tighten:  Tighten the coolant pipe bracket bolt to 10 N.m (89 lb in).

    65. Fig 31: View of Ignition Module Housing Assembly With Spark Plug Boots
    GM951506Courtesy of GENERAL MOTORS CORP.
  65. Install the spark plugs, if removed.

    Tighten:  Tighten the spark plugs to 20 N.m (15 lb ft).

  66. Install the ignition module assembly to the cam cover and hand-tighten the retaining bolts.

    Tighten:  Tighten the ignition module-to-camshaft cover bolts to 8 N.m (71 lb in).

    67. Fig 32: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  67. Install the air cleaner assembly and bolt.

    Tighten:  Tighten the air cleaner-to-support bracket bolt to 10 N.m (89 lb in).

  68. Install the outlet resonator/duct assembly into position.
  69. Connect the PCV fresh air vent hose assembly.
  70. Tighten the clamp at the throttle body assembly.
  71. Position the outlet resonator/duct assembly up with support bracket and install push-pin.
  72. Tighten the clamp at the air cleaner assembly.
  73. Connect the intake air temperature (IAT) sensor connector.
  74. Connect the negative battery cable.

    Tighten:  Tighten the battery terminal bolt to 17 N.m (13 lb ft).

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