LEMON Manuals: Even more car manuals for everyone
Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 548 (Engine Mechanical - 2.2L) >> Removal And Installation >> In-Vehicle >> Camshaft Replacement >> Removal

Camshaft 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.
    Fig 1: Removing Outlet Resonator/Duct Assembly
    G01039166Courtesy of GENERAL MOTORS CORP.
  8. Disconnect electrical connector at ignition module.
  9. Remove ignition module assembly with bolts.
  10. Disconnect coolant de-gas hose clip on fuel rail.
    Fig 2: Removing Ignition Module Assembly With Bolts
    G01039167Courtesy of GENERAL MOTORS CORP.
  11. Disconnect ground strap at rear of cam cover assembly.
    Fig 3: Disconnecting Ground Strap At Rear Of Cam Cover Assembly
    G01039168Courtesy 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 fuel rail assembly.
  12. Relieve fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
  13. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
    Fig 4: Disconnecting Gauge Bar Set
    G01039169Courtesy of GENERAL MOTORS CORP.
  14. Disconnect fuel rail bracket and bolt at rear of cam cover.
  15. While supporting the fuel rail assembly with an open-end wrench, loosen transfer line fitting at fuel rail.
    Fig 5: Disconnecting Fuel Rail Bracket And Bolt At Rear Of Cam Cover
    G01039170Courtesy of GENERAL MOTORS CORP.
  16. Position fuel line away from cam cover assembly.
    Fig 6: Position Fuel Line Away From Cam Cover Assembly
    G01039171Courtesy of GENERAL MOTORS CORP.
  17. Remove cam cover assembly bolts.
  18. Remove cam cover assembly.
    Fig 7: Removing Cam Cover Assembly
    G01039172Courtesy of GENERAL MOTORS CORP.
  19. Remove purge solenoid from power steering plate.
  20. Remove power steering block off plate if intake camshaft is being removed.
    Fig 8: Removing Purge Solenoid From Power Steering Plate
    G01039173Courtesy 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 position.

    IMPORTANT:  To rotate camshafts, 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.
    NOTE: Care should be taken removing guide bolts to avoid from falling down into front cover.
    Fig 9: Rotating Camshaft Sprockets
    G01039174Courtesy of GENERAL MOTORS CORP.
  22. Remove upper timing chain guide.
    NOTE: During camshaft removal procedure, the pistons are locked in position by Camshaft Support Holding J43655 tool. DO NOT rotate engine crankshaft or tool damage and timing reset will be required. Camshafts can be rotated ONLY AFTER #1 piston is at 60° before top dead center (BTDC) and sprocket had been disengaged from camshaft.
  23. Remove front camshaft caps.
    Fig 10: Removing Upper Timing Chain Guide
    G01039175Courtesy of GENERAL MOTORS CORP.

    IMPORTANT:  Lubricate sprocket pins with clean motor oil. These will allow sprockets to easily slide on sprocket pins.

  24. Install J43655 through sprocket holes from timing chain side of sprocket towards rear of engine.
  25. With guide pin installed in sprocket, align guide pins into slots on support plate.
    Fig 11: Installing J43655 Through Sprocket Holes
    G01039176Courtesy of GENERAL MOTORS CORP.
  26. Tighten support bracket to cylinder head.

    Torque: 

    Support Plate to Cylinder Head: 10 N.m (89 in-lbs) 

  27. Install wing nuts and tighten.
    Fig 12: Installing Wing Nuts
    G01039177Courtesy of GENERAL MOTORS CORP.
  28. Hold each camshaft in place using 24 mm open end wrench and carefully remove camshaft sprocket timing retaining bolts and washers. Discard torque-to-yield (TTY) bolts.

    IMPORTANT:  When sliding timing chain and sprockets onto guide pins, be sure timing chain is positioned properly on adjustable and fixed guide or guide damage will occur. Care should be taken when removing camshaft sprockets from camshafts.

    IMPORTANT:  Camshafts are spring loaded and may rotate. Care should be taken until all spring tension is removed from camshaft.

  29. Slide camshaft sprockets away from camshafts.
  30. To release spring tension on camshaft, after camshaft is disengaged from sprocket, rotate camshaft using a 24 mm wrench to a neutral position.
    Fig 13: Removing Camshaft Sprocket Timing Retaining Bolts And Washer
    G01039178Courtesy of GENERAL MOTORS CORP.
  31. Uniformly loosen and remove remaining camshaft bearing cap bolts.
    Fig 14: Loosening And Removing Remaining Camshaft Bearing Cap Bolts
    G01039179Courtesy of GENERAL MOTORS CORP.
  32. Carefully pull camshaft(s) straight up to avoid damaging cylinder head thrust surfaces.
    Fig 15: Pulling Camshaft(s) Straight Up
    G01039180Courtesy of GENERAL MOTORS CORP.
scientia non olet · About LEMON Manuals