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Home >> Saturn >> 2006 >> Vue Red Line, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Cylinder Head Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
    Fig 1: Inspecting Timing Chain Guide
    GM897477Courtesy of GENERAL MOTORS CORP.
    NOTE: Set crankshaft to 60 degrees before top-dead center or after TDC to prevent valve to piston contact.
  1. Transfer all components. (intake manifold, plugs, ect.)
    2. Fig 2: Setting Mark On The Timing Chain Drive Sprocket At 5 O'clock Position
    GM895036Courtesy of GENERAL MOTORS CORP.
  2. Set crankshaft to 60 degrees before top dead center.
    3. Fig 3: Inspecting Timing Chain Guide
    GM897477Courtesy of GENERAL MOTORS CORP.
  3. Install the cylinder head gasket placing OPEN facing up.
    4. Fig 4: Cylinder Head Bolt Tightening Sequence
    GM895413Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Always use new cylinder head bolts.
  4. With assistance, install cylinder head, aligning it onto cylinder head dowels.
  5. Lightly apply clean engine oil to threads and to the bottom side of flange of head bolts. Allow oil to drain before installing.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install and torque cylinder head bolts in sequence.

    Tighten:  Tighten the cylinder head bolts to 30 N.m (22 lb ft) + 155 degrees.

    7. Fig 5: View Of Front Cylinder Head Crankcase Bolts
    GM894993Courtesy of GENERAL MOTORS CORP.
  7. Coat the front cylinder head crankcase bolts with Permatex® Threadlocker® Blue P/N 21485278, or equivalent.

    Tighten:  Tighten the cylinder head front chaincase bolts to 35 N.m (24 lb ft).

    8. Fig 6: Installing SA9105E Set Up For SUV Application
    GM952023Courtesy of GENERAL MOTORS CORP.
  8. Install the SA9105E  that was removed earlier. See Special Tools .
    9. Fig 7: Positioning Exhaust Camshaft
    GM895039Courtesy of GENERAL MOTORS CORP.
  9. Position the exhaust camshaft with offset slot to the 10 o'clock position.
    10. Fig 8: Positioning Intake Camshaft
    GM895009Courtesy of GENERAL MOTORS CORP.
  10. Position the intake camshaft with offset slot to the 2 o'clock position.
    11. Fig 9: Removing/Installing Timing Chain Drive Sprocket
    GM897597Courtesy of GENERAL MOTORS CORP.
  11. Install timing chain drive sprocket to the crankshaft.
  12. Using dampener, rotate the crank so that the mark on the timing chain drive sprocket is at the 5 o'clock position.
    13. Fig 10: Removing & Installing Timing Chain Oiling Nozzle
    GM895210Courtesy of GENERAL MOTORS CORP.
  13. Install timing chain oiling nozzle and bolt.

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

    14. Fig 11: Positioning Intake Camshaft
    GM895009Courtesy of GENERAL MOTORS CORP.
  14. Assemble the chain to the intake camshaft sprocket aligning the copper link to INT diamond timing mark on camshaft sprocket.
    15. Fig 12: 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 assembly back to that the camshaft sprocket is facing forward.
  15. Lower 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.
    16. Fig 13: 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.
  16. Route chain around crankshaft sprocket and align silver link to timing mark.
    17. Fig 14: 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.
  17. Install the intake camshaft sprocket with the chain in the proper position to the camshaft. Rotate the intake camshaft using a 24 mm wrench on flats on camshaft until camshaft aligns with sprocket.
    18. IMPORTANT: With the timing chain aligned to crankshaft sprocket mark, the crankshaft can be rotated slightly to eliminate slack from the fixed side of the timing chain. Be sure that the marks are properly aligned.
  18. Install new intake camshaft sprocket bolt and finger tighten.
    19. Fig 15: Timing Chain Adjustable Guide And Bolt
    GM894967Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Make sure the crankshaft marks and the camshaft marks aligns with the colored links.
  19. Install adjustable timing chain guide through the opening at the top of the cylinder head and install chain guide bolt.

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

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

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

    27. Fig 20: Fixed Timing Chain Guide Access Plug
    GM894968Courtesy of GENERAL MOTORS CORP.
  27. Apply thread sealant Permatex® Thread Pipe Sealant (or equivalent) compound to the thread. Install the fixed guide bolt access hole plug.

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

    28. Fig 21: 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.
  28. Tighten the intake and exhaust camshaft sprocket bolts while holding the camshaft with 24 mm wrench.

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

    29. Fig 22: Inspecting Timing Chain Tensioner
    GM946995Courtesy of GENERAL MOTORS CORP.
  29. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring or washer is damaged replace the timing chain tensioner.
    30. 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 (3.35 in) (1) from end to end.
  30. Measure the timing chain tensioner assembly from end to end.
    31. Fig 23: Compressing Timing Chain Tensioner
    GM797246Courtesy of GENERAL MOTORS CORP.
  31. 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 J 45027  (2) into a vise. See Special Tools .
    3. Install notch end of piston assembly into J 45027  (2). See Special Tools .
    4. Using J 45027  (1), turn the ratchet cylinder into the piston. See Special Tools .
    32. Fig 24: Inspecting Timing Chain Tensioner
    GM946995Courtesy of GENERAL MOTORS CORP.
  32. 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 lint free cloth.
  33. 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.
  34. 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 30.
    35. Fig 25: Removing/Installing Timing Chain Tensioner Assembly
    GM894951Courtesy of GENERAL MOTORS CORP.
  35. Ensure all dirt and debris is removed from the timing chain tensioner threaded hold in the cylinder head.
  36. Install new timing chain tensioner assembly and tighten.

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

  37. 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.
    38. Fig 26: Removing/Installing Upper Timing Chain Guide
    GM894944Courtesy of GENERAL MOTORS CORP.
  38. Install upper timing chain guide and bolts.

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

  39. Raise the vehicle if necessary.
  40. Install new front cover gasket.
  41. Install the front cover assembly.
  42. Install the front cover assembly bolts.

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

  43. Install the front cover water pump bolts.

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

    44. Fig 27: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
    GM895194Courtesy of GENERAL MOTORS CORP.
  44. Lubricate the front seal and sealing surface of the pulley with clean motor oil.
  45. Install balancer pulley onto crankshaft indexing keyway. Use care to properly align flats on balancer pulley with flats on oil pump drive in front cover assembly.
  46. Install the crankshaft damper pulley.
    47. Fig 28: Removing & Installing Damper Assembly
    GM895197Courtesy of GENERAL MOTORS CORP.
  47. Install new crankshaft balancer pulley bolt with washer assembly.
    48. Fig 29: Removing & Installing Harmonic Balancer Using Holder On Damper Assembly
    GM895194Courtesy of GENERAL MOTORS CORP.
  48. Install crankshaft pulley holder J 38122-A  . See Special Tools .

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

    49. Fig 30: Depressing Tensioner Arm
    GM896375Courtesy of GENERAL MOTORS CORP.
  49. Install accessory drive belt tensioner.

    Tighten:  Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

  50. Route belt around the alternator and the A/C compressor.
  51. Install J 39914  onto tensioner and upload spring tension from tensioner while positioning belt. See Special Tools .
  52. Release tensioner and remove the tool
  53. Position manifold down pipe with gasket onto flange studs.
  54. Install exhaust manifold pipe to exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold nuts to 30 N.m (22 lb ft).

  55. Attach electrical harness at bottom intake manifold.
  56. Position oil level indicator into oil pan assembly.
  57. Install oil level indicator tube bolt.

    Tighten::  Tighten the oil level indicator-to-manifold bolt to 10 N.m (89 lb in).

  58. Remove the oil drain plug and drain oil.

    Tighten:  Tighten the oil drain plug to 25 N.m (18 lb ft).

  59. Lower the vehicle.
  60. Remove the oil filter and install a new oil filter.
  61. Fill the engine with oil.

    Tighten:  Tighten the oil filter cap to 25 N.m (18 lb ft)

    62. Fig 31: Removing/Installing Right Hand Engine Mount Bracket
    GM928024Courtesy of GENERAL MOTORS CORP.
  62. Install right-hand engine bracket and bolts.

    Tighten:  Tighten the engine mount bracket-to-engine bolts to 90 N.m (66 lb ft).

    63. Fig 32: View Of RH Engine Mount
    GM928650Courtesy of GENERAL MOTORS CORP.
  63. Install shims on right hand engine mount studs.
  64. Install right-hand engine mount onto body side rail studs.
  65. Install right-hand engine mount to body nuts.

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

  66. Install right-hand engine mount to engine mount bracket bolts.

    Tighten:  Tighten engine mount-to-engine mount bracket bolts to 55 N.m (41 lb ft).

  67. Install the right engine inner splash shield.
  68. Install the right wheel and hand-tighten wheel nuts.
  69. Tighten wheel nuts.

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

    70. Fig 33: Installing SA9105E Set Up For SUV Application
    GM952023Courtesy of GENERAL MOTORS CORP.
  70. Remove three bar engine support fixture.
    71. Fig 34: Removing/Installing Cam Cover Assembly
    GM894940Courtesy of GENERAL MOTORS CORP.
  71. Visually inspect the camshaft cover gasket for signs of leakage. Camshaft cover gasket is reusable if not damaged.
  72. Assemble the camshaft cover and gasket using care to make sure that the gasket is located in the retaining groove on the camshaft cover.
  73. Install cover on the cylinder head and tighten the bolts.

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

    74. Fig 35: Removing/Installing ECM Assembly & Bolts
    GM947702Courtesy of GENERAL MOTORS CORP.
  74. Position engine harness and install fasteners at cam cover.
  75. Connect the throttle body connector.
  76. Attach ECM ground and ECM connector.
  77. Connect the fuel injector harness.
  78. Connect the upper radiator hose.
  79. Connect the brake booster hose at booster
  80. Connect EVAP purge hose and connector.
  81. Connect the oxygen sensors at the exhaust manifold.
    82. Fig 36: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
  82. Reposition the fuel line assembly.
    83. 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.
  83. Install transfer line at fuel-to-fuel rail.

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

    84. Fig 37: View Of Fuel Feed Pipe Fastener
    GM854304Courtesy of GENERAL MOTORS CORP.
  84. 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).

    85. Fig 38: Disconnecting/Connecting Ground Strap On The Camshaft Cover Assembly
    GM895199Courtesy of GENERAL MOTORS CORP.
  85. Connect the ground strap to the camshaft cover assembly.

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

  86. Connect the degas hose and attach to the fuel fail.
  87. Connect the coolant pipe bracket bolts to the cylinder head.

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

    88. Fig 39: View of Ignition Module Housing Assembly With Spark Plug Boots
    GM951506Courtesy of GENERAL MOTORS CORP.
  88. Install spark plugs, if removed.

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

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

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

    90. Fig 40: Identifying Outlet Resonator/Duct Assembly
    GM898897Courtesy of GENERAL MOTORS CORP.
  90. Install air cleaner assembly and bolt.

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

  91. Install outlet resonator/duct assembly into position.
  92. Connect PCV fresh air vent hose assembly.
  93. Tighten clamp at throttle body assembly.
  94. Position outlet resonator/duct assembly up with support bracket and install push-pin.
  95. Tighten the clamp at the air cleaner assembly.
  96. Connect intake air temperature (IAT) sensor connector.
  97. Install coolant. Refer to Draining and Filling Cooling System (GE 47716 Fill) or Draining and Filling Cooling System (Static Fill) in Engine Cooling.
  98. Connect negative battery cable.

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

  99. Start the vehicle and inspect for leaks.
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