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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.0L) >> Repair Instructions >> On-Vehicle Repair Instructions >> Timing Chain, Sprockets, and/or Tensioner Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: View Of Upper Balance Shaft Drive Chain Guide
    GM412415Courtesy of GENERAL MOTORS CORP.
    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.
  1. Install the upper balance shaft chain guide.

    Tighten:  Tighten the upper balance shaft chain guide bolts to 15 N.m (11 lb ft).

    2. Fig 2: Aligning Balance Shaft Drive Chain
    GM412520Courtesy of GENERAL MOTORS CORP.
  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.

    1. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
    2. 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).
    3. Place the chain (3) on the water pump drive sprocket (alignment is not critical).
    4. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.
    3. Fig 3: Exploded View Of Small Balance Shaft Drive Chain Guide
    GM412414Courtesy of GENERAL MOTORS CORP.
  3. Install the small balance shaft chain guide.
  4. Tighten the balance shaft chain guide bolts.

    Tighten:  Tighten the chain guide bolts to 15 N.m (11 lb ft).

    5. Fig 4: View Of Adjustable Balance Shaft Chain Guide
    GM412413Courtesy of GENERAL MOTORS CORP.
  5. Install the adjustable balance shaft drive chain guide.

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

    6. Fig 5: View Of Timing Chain Tensioner
    GM412528Courtesy of GENERAL MOTORS CORP.
  6. 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.
  7. Install the timing chain tensioner.
  8. Tighten the chain tensioner bolts.

    Tighten:  Tighten the chain tensioner bolts to 10 N.m (89 lb in).

  9. Remove the paper clip from the balance shaft drive chain tensioner.
    10. Fig 6: View Of Oil Nozzle & Bolt
    GM412200Courtesy of GENERAL MOTORS CORP.
  10. Install the oil nozzle and bolt.

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

    11. Fig 7: View Of Crankshaft Sprocket Timing Mark
    GM466551Courtesy of GENERAL MOTORS CORP.
  11. Install the crankshaft sprocket with timing mark at the 5 o'clock position.
    12. Fig 8: Locating Cylinder Block Bosses
    GM412535Courtesy of GENERAL MOTORS CORP.
  12. 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).
    13. Fig 9: Aligning Timing Chain Link & Intake Sprocket Timing Mark
    GM466558Courtesy of GENERAL MOTORS CORP.
  13. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position.
    14. IMPORTANT: Always install NEW sprocket bolts.
  14. Hand tighten a NEW intake camshaft sprocket bolt.
  15. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark.
  16. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.
    17. Fig 10: View Of Timing Chain Tensioner Guide
    GM412160Courtesy of GENERAL MOTORS CORP.
  17. 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).

    18. Fig 11: Aligning Timing Chain Link & Exhaust Timing Mark
    GM466570Courtesy of GENERAL MOTORS CORP.
  18. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position.
    19. Fig 12: Using 24 mm Wrench To Align Camshaft
    GM412536Courtesy of GENERAL MOTORS CORP.
  19. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.
    20. IMPORTANT: Always install NEW sprocket bolts.
  20. Hand tighten the NEW exhaust camshaft sprocket bolt.
    21. Fig 13: View Of Fixed Timing Chain Guide
    GM412165Courtesy of GENERAL MOTORS CORP.
  21. Install the fixed timing chain guide.

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

    22. Fig 14: View Of Fixed Timing Chain Guide Access Plug
    GM412164Courtesy of GENERAL MOTORS CORP.
  22. Apply sealant, GM P/N 12378521 (Canadian P/N 88901148) compound to thread and install the timing chain guide bolt access hole plug.

    Tighten:  Tighten the chain guide plug to 90 N.m (59 lb ft).

    23. Fig 15: View Of Upper Timing Chain Guide
    GM412167Courtesy of GENERAL MOTORS CORP.
  23. Install the timing chain upper guide.

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

    24. Fig 16: Measuring Timing Chain Tensioner Assembly
    GM714496Courtesy of GENERAL MOTORS CORP.
  24. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
  25. 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.

    26. Fig 17: Compressing Timing Chain Tensioner
    GM797246Courtesy of GENERAL MOTORS CORP.
  26. 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.
    27. Fig 18: Measuring Timing Chain Tensioner Assembly
    GM714496Courtesy of GENERAL MOTORS CORP.
  27. 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.
  28. 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.
  29. 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 26.1 through 26.4.
    30. Fig 19: Identifying Timing Chain Tensioner
    GM412158Courtesy of GENERAL MOTORS CORP.
  30. Install the timing chain tensioner.

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

  31. 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.
    32. Fig 20: Holding Camshaft Stationary With Wrench On Hex Casting On Camshaft
    GM630311Courtesy of GENERAL MOTORS CORP.
  32. 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.

  33. Install the camshaft cover. Refer to Camshaft Cover Replacement .
  34. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  35. Install the engine front cover. Refer to Engine Front Cover Replacement .
  36. Lower the vehicle.
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