Info - Timing Chain Design Change And Revised Service .
Document ID# 1341990Info - Timing Chain Design Change andRevised Service Procedures #03-06-01-017- (Jun 9, 2003)Service Information -- Timing Chain Design Change and Revised Service Procedures2000-2003 Saturn L-Series with 2.2L Engine (VIN F -- RPO L61)2002-2003 Saturn VUE with 2.2L Engine (VIN D -- RPO L61)2003 Saturn ION VehiclesGeneral Manager, Fixed Operations Manager, TechnicianPurposeThe purpose of this bulletin is to communicate updated service procedures to the timingchain and timing chain oiling nozzle due to design changes that have been made to bothcomponents. All timing chain kits now available in service will include the oiler nozzle.This new nozzle has higher flow rate characteristics that will increase oil flow to thetiming chain under low RPM operating conditions. Whenever replacing a timing chain, itis important to replace the oiler nozzle.Prior edition Service Manuals for the above listed vehicles refer to the timing chain indexlinks being colored "silver" and "copper." With the implementation of the newer designchain and oiler assembly, the index link colors have changed. In order to avoid confusion,the service procedure text has been modified to refer to the index links as two commoncolored and one unique colored link. Please use the procedure in this bulletin to replaceall previously issued Service Manuals.The eSI website will be updated immediately and future Service Stall System SI CDreleases will include this and other Service Manual updates.Service Procedure
Removal Procedure1. Disconnect negative battery cable. Refer to Battery Negative CableDisconnect/Connect in the appropriate model and model year Engine ServiceManual.2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in theGeneral Information section of the appropriate model and model year ServiceManual.3. Remove the engine front cover. Refer to Engine Front Cover Replacement in theappropriate model and model year Engine Service Manual.Important: The timing chain has two matching colored links and one uniquelycolored link.4. Rotate the engine until the crankshaft sprocket mark aligns with the matchingcolored link (2) at the 5 o'clock position.5. Lower the vehicle.6. Remove the camshaft cover. Refer to Camshaft Cover Replacement in theappropriate model and model year Engine Service Manual.
7. Ensure that the INT diamond on the intake camshaft sprocket is aligned with theuniquely colored link (1) at the 2 o'clock position.8. Ensure that the EXH triangle on the exhaust camshaft sprocket is aligned with thematching colored link (3).
9. Remove the timing chain tensioner.
10. Remove the fixed timing chain guide access plug.11. Remove the fixed timing chain guide.
12. Remove the upper timing chain guide.13. Use a 24 mm wrench to hold the camshaft from turning.14. Remove the exhaust camshaft sprocket bolt and discard.
15. Remove the exhaust camshaft sprocket.16. Remove the timing chain tensioner guide.17. Remove the intake camshaft sprocket bolt and discard.18. Remove the intake camshaft sprocket.
19. Remove the timing chain through the top of the cylinder head.20. Remove the crankshaft sprocket.21. Remove the oil nozzle and bolt.Installation Procedure
1. Install the oil nozzle and bolt.TightenTighten the Timing Chain Oil Nozzle Bolt to 10 N·m (89 in-lbs)
2. Install the crankshaft sprocket with timing mark at the 5 o'clock position.3. 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 blockbosses (1, 2).4. Install the intake camshaft sprocket with the INT diamond at the 2 o'clockposition.Important: Always install NEW sprocket bolts.
5. Hand tighten a NEW intake camshaft sprocket bolt. Refer to the appropriatemodel year and model Saturn Parts and Illustration catalog for the correct partnumber of the new intake camshaft sprocket bolt.6. Route the timing chain around the crankshaft sprocket with the matching coloredlink aligning with the timing mark.7. Route the timing chain around the intake camshaft sprocket with the uniquelycolored link (1) aligning with the INT diamond.8. Install the timing chain tensioner guide through the opening in the top of thecylinder head.TightenTighten the timing chain tensioner guide bolt to 10 N·m (89 lb in).
9. Install the exhaust camshaft sprocket with the timing chain matching colored link(3) at EXH triangle aligned at the 10 o'clock position.10. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket alignswith the camshaft.Important: Always install NEW sprocket bolts.
11. Hand tighten the NEW exhaust camshaft sprocket bolt. Refer to the appropriatemodel year and model Saturn Parts and Illustration catalog for the correct partnumber of the new exhaust camshaft sprocket bolt.12. Install the fixed timing chain guide.TightenTighten the fixed timing chain bolts to 10 N·m (89 lb in).
13. Apply sealant, Saturn P/N 21485277 (in Canada, 10953489) compound to threadand install the timing chain guide bolt access hole plug.TightenTighten the chain guide plug to 40 N·m (30 lb ft).14. Install the timing chain upper guide.TightenTighten the timing chain upper guide bolts to 10 N·m (89 lb in).15. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, orwasher is damaged, replace the timing chain tensioner.
16. Measure the timing chain tensioner assembly from end to end. A new tensionershould be supplied in the fully compressed non-active state. A tensioner in thecompressed state will measure 72 mm (2.83 in) from end to end (refer toillustration [a]). A tensioner in the active state will measure 85 mm (3.35 in) fromend to end (refer to illustration [a]).17. If the timing chain tensioner is not in the compressed state, perform the followingsteps:A. Remove the piston assembly from the body of the timing chain tensionerby pulling it out.
B. Install the J 45027-2 (2) into a vise.C. Install the notch end of the piston assembly into the J 45027-2 (2).D. Using the J 45027-1 (1), turn the ratchet cylinder into the piston.18. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damageappears, replace the tensioner. Clean dirt or debris out with a lint free cloth.19. Install the compressed piston assembly back into the timing chain tensioner bodyuntil it stops at the bottom of the bore. Do not compress the piston assemblyagainst the bottom of the bore. If the piston assembly is compressed against thebottom of the bore, it will activate the tensioner, which will then need to be resetagain.20. At this point, the tensioner should measure approximately 72 mm (2.83 in) fromend to end (refer to illustration [a]). If the tensioner does not read 72 mm (2.83 in)from end to end (refer to illustration [a]), repeat steps 17.1 through 17.4.
21. Install the timing chain tensioner.TightenTighten the timing chain tensioner to 75 N·m (55 lb ft).22. Use a suitable tool with a rubber tip on the end. Feed the tool down through thecamshaft drive chain to rest on the timing chain. Then give a sharp jolt diagonallydownwards to release the tensioner.23. Use a 24 mm wrench to hold the camshaft.
TightenTighten the NEW camshaft bolts to 85 N·m (63 lb ft) plus 30 degrees.24. Install the camshaft cover. Refer to Camshaft Cover Replacement in theappropriate model and model year Engine Service Manual.25. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in theGeneral Information section of the appropriate model and model year ServiceManual.26. Install the engine front cover. Refer to Engine Front Cover Replacement in theappropriate model and model year Engine Service Manual.27. Lower the vehicle.28. Connect negative battery cable. Refer to Battery Negative CableDisconnect/Connect in the appropriate model and model year Engine ServiceManual.GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". Theyare written to inform these technicians of conditions that may occur on some vehicles, or toprovide information that could assist in the proper service of a vehicle. Properly trainedtechnicians have the equipment, tools, safety instructions, and know-how to do a job properlyand safely. If a condition is described, DO NOT assume that the bulletin applies to yourvehicle, or that your vehicle will have that condition. See your GM dealer for information onwhether your vehicle may benefit from the information.WE SUPPORTVOLUNTARYTECHNICIANCERTIFICATION Copyright General Motors Corporation. All Rights Reserved.Document ID# 1341990
Info - Timing Chain Design Change and Revised Service Procedures #03-06-01-017 - (Jun 9, 2003) . Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark. 7. Route the timing chain around the in
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If the original timing chain markings are not legible, use paint or equivalent to mark the timing chains to the sprockets. 4. If removing the secondary timing chains, loosen camshaft sprocket bolts. 5. Compress the primary timing chain tensioner. 1. Loosen clip of primary timing chain tensioner, and release plunger stopper (1). 2.
EM-28 1GR-FE ENGINE MECHANICAL - TIMING CHAIN EM (b) Align the yellow mark link with the timing mark of the crankshaft timing link. (c) Align the orange mark links with the timing marks of the camshaft timing gears, and install the chain. 4. INSTALL NO. 2 CHAIN VIBRATION DAMPER (a) Install the 2 No. 2 chain vibration dampers. 5.
Jan 06, 2011 · NOTE: Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain. LH side 30. Remove the LH side hydraulic chain tensioner. 31. Install the .
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tensioner. 37. Carefully cut the RTV between the timing chain cover and the oil pan gasket. 38. Lower the vehicle. 39. Remove the timing chain cover bolts (Figure 7). 40. Remove the timing chain cover (Figure 7). 41. Remove the front crankshaft seal from the timing chain cover and discar
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