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Timing Chain Replacement: Removal

WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable.
  2. Disconnect intake air temperature (IAT) sensor connector.
  3. Loosen clamp at air cleaner assembly.
  4. Remove push pin attachment from outlet resonator/duct assembly to support bracket.
  5. Loosen clamp at throttle body assembly.
  6. Disconnect PVC fresh air vent hose at cam cover.
  7. Remove outlet resonator/duct assembly.
  8. Remove air cleaner assembly hold-down bolt.
  9. Remove air cleaner assembly.
    Fig 1: Removing Outlet Resonator/Duct Assembly
    G01039380Courtesy of GENERAL MOTORS CORP.
  10. Remove ignition module bolts.
  11. Remove ignition module assembly.
    Fig 2: Removing Ignition Module Assembly
    G01039381Courtesy of GENERAL MOTORS CORP.
  12. Disconnect de-gas hose at clamp at cylinder head and unclip from fuel rail. Position away from cam cover assembly.
  13. Disconnect ground strap at rear of cam cover assembly.
    Fig 3: Disconnecting Ground Strap At Rear Of Cam Cover Assembly
    G01039382Courtesy of GENERAL MOTORS CORP.
  14. Relieve fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  15. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
    Fig 4: Disconnecting Gauge Bar Set
    G01039383Courtesy of GENERAL MOTORS CORP.
  16. Disconnect fuel rail bracket and bolt at rear of cam cover.
    Fig 5: Disconnecting Fuel Rail Bracket
    G01039384Courtesy of GENERAL MOTORS CORP.
    CAUTION: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING TO COLLECT FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.
    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.
  17. While supporting the fuel rail assembly with an open-end wrench, loosen transfer line fitting at fuel rail.
    Fig 6: Loosening Transfer Line Fitting At Fuel Rail
    G01039385Courtesy of GENERAL MOTORS CORP.
  18. Position fuel line away from cam cover assembly.
  19. Remove cam cover assembly bolts.
  20. Remove cam cover assembly.
    Fig 7: Removing Cam Cover Assembly
    G01039386Courtesy of GENERAL MOTORS CORP.
    NOTE: To avoid valve to piston contact, No.1 piston must be positioned at approximately 60° before top dead center (BTDC). Pistons are properly positioned when diamond shaped hole on intake camshaft sprocket is located at 12 o'clock.

    IMPORTANT:  To rotate camshaft(s), use a 24 mm open-end wrench on camshaft flats. Camshaft(s) should be rotated in a clockwise direction only (facing camshaft sprockets from passenger side of vehicle).

  21. Locate the No. 1 piston to approximately 60° before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove spark plugs. This will ease rotation effort.
    Fig 8: Rotating Camshaft Sprocket
    G01039387Courtesy of GENERAL MOTORS CORP.
  22. Remove upper timing chain guide.
    Fig 9: Removing Upper Timing Chain Guide
    G01039388Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The timing chain tensioner must be removed to unload chain tension before timing chain is removed. If it is not removed, the timing chain may bind and be difficult to remove.

  23. Remove timing chain tensioner.
    Fig 10: Removing Timing Chain Tensioner
    G01039389Courtesy of GENERAL MOTORS CORP.
  24. Remove fixed timing chain guide access plug.
  25. Using a magnetic socket, remove upper fixed guide bolt.
    Fig 11: Removing Upper Fixed Guide Bolt
    G01039390Courtesy of GENERAL MOTORS CORP.
  26. Install Engine Three Bar Fixture SA9105E set up for SUV application. (Also, use Engine Support Adapter J45122 with long hooks from Engine Support Fixture Adaptor J43405).
    Fig 12: Installing Engine Three Bar Fixture
    G01039391Courtesy of GENERAL MOTORS CORP.
  27. Remove right-hand engine mount-to-bracket bolts.
  28. Remove right-hand mount assembly nuts.
  29. Remove right-hand engine mount assembly.
    Fig 13: Removing Right-Hand Engine Mount Assembly
    G01039392Courtesy of GENERAL MOTORS CORP.
  30. Remove right-hand mount bracket.
    Fig 14: Removing Right-Hand Mount Bracket
    G01039393Courtesy of GENERAL MOTORS CORP.
  31. Remove right-hand engine mount bracket.
  32. Raise vehicle on hoist.
  33. Remove right wheel and splash shield.

    IMPORTANT:  Do not rest engine assembly on oil pan plug outside of oil pan near crankshaft or an oil leak may result.

  34. Install block of wood (1x2x4) between oil pan and cradle.
  35. Install Accessory Belt Tensioner Unloader J44811 tool.
  36. Remove accessory drive belt.
  37. Remove tensioner bolt. To remove bolt, an access hole has been provided through the inner and outer engine rail.
  38. Remove tensioner assembly.
    Fig 15: Removing Tensioner Assembly
    G01039394Courtesy of GENERAL MOTORS CORP.
  39. Install Crankshaft Pulley Holder J38122A.
    Fig 16: Installing Crankshaft Pulley Holder
    G01039395Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  The crankshaft balancer pulley bolt head and washer assembly prevents oil leakage at center of pulley. Do not damage sealing surfaces. If pulley cannot be removed by pulling with hand, use a three-jaw puller.

  40. Remove crankshaft balancer pulley bolt and pulley. Discard pulley bolt.
    Fig 17: Removing Crankshaft Balancer Pulley Bolt And Pulley
    G01039396Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  To avoid damage to the front cover assembly, do not pry against cover.

  41. Remove front cover assembly bolts.
  42. Remove lower water pump assembly bolt.
  43. Remove front cover assembly and gasket.
    Fig 18: Removing Front Cover Assembly Bolts
    G01039397Courtesy of GENERAL MOTORS CORP.
  44. Remove adjustable guide bolt.
    Fig 19: Removing Adjustable Guide Bolt
    G01039398Courtesy of GENERAL MOTORS CORP.
  45. Remove lower fixed guide bolt.
  46. Remove fixed guide.
    Fig 20: Removing Fixed Guide
    G01039399Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
  47. Use a 24 mm wrench to hold camshaft assembly while removing the exhaust sprocket bolt. Discard bolt.
  48. Remove exhaust sprocket.
    Fig 21: Removing Exhaust Sprocket
    G01039400Courtesy of GENERAL MOTORS CORP.
  49. Remove adjustable guide through the top of cylinder head.
    Fig 22: Removing Adjustable Guide
    G01039401Courtesy of GENERAL MOTORS CORP.
    NOTE: The camshaft sprocket bolts are torque-to-yield bolts and are not reusable. They must be replaced when removed.
  50. Use a 24 mm wrench to hold camshaft assembly while removing intake sprocket bolt. Discard bolt.
  51. Remove intake sprocket.
  52. Remove timing chain assembly through top of cylinder head.
  53. Remove timing chain drive sprocket from crankshaft.
    Fig 23: Removing Timing Chain Assembly
    G01039402Courtesy of GENERAL MOTORS CORP.
    NOTE: Replace timing chain guides if wear exceeds 1.12 mm (0.045 in.).
  54. Inspect timing chain guide for wear.
  55. Inspect timing chain and sprockets for signs of excessive wear, chipping, or seizure to links on chain.
    Fig 24: Inspecting Timing Chain And Sprockets
    G01039403Courtesy of GENERAL MOTORS CORP.
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