04 sun fire timing

8/14/2019 04 Sun Fire Timing

1/23

iming Chain, Sprockets, and/or Tensioner Replacement

Removal Procedure

1. Disconnect the negative battery cable.

2. Remove the camshaft cover.

3. Raise and support the vehicle. Refer to Vehicle Lifting.

4. Remove the engine front cover.

5. Rotate the engine until the crankshaft sprocket mark aligns with the secondsilver link (2) at the 5 o'clock position.

6. Lower the vehicle.

7. Remove the camshaft cover.

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2/23

8. Ensure that the INT diamond on the intake camshaft sprocket is aligned withthe copper link at (1) at the 2 o'clock position.

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3/23

9. Ensure that the EXH triangle on the exhaust camshaft sprocket is aligned withthe silver link (3).

10.Remove the timing chain tensioner.

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4/23

11.Remove the timing chain tensionerguide.

12.Remove the engine mount.

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5/23

13.Remove the fixed timing chain guideaccess plug.

14.Remove the fixed timing chain guide.

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6/23

15.Remove the uppertiming chain guide.

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7/23

16.Use a 24 mm wrench to hold the camshafts from turning.

17. Remove the exhaust camshaft sprocket bolt and discard.

18. Remove the exhaust camshaft sprocket.

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8/23

19. Remove the intake camshaft sprocket bolt and discard.

20. Remove the intake camshaft sprocket.

21. Remove the timing chain through the top of the cylinder head.

22. Remove the crankshaft sprocket.

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9/23

23.Remove the balance shaft drive chain tensioner.

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10/23

24.Remove the adjustable balance shaft chain guide.

25.Remove the small balance shaft drive chain guide.

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11/23

26.Remove the upperbalance shaft drive chain guide.

Notice: It may ease removal of the balance shaft drive chain to get all of the slack in thechain between the crankshaft andwater pump sprockets.

27.Remove the balance shaft drive chain.

Installation Procedure

Tools Required

J 45027 Tensioner Tool

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12/23

Important: If the balance shafts are not properly timed to the engine, the engine mayvibrate and make noise.

Notice: Refer to Fastener Notice in Service Precautions.

1. Install the upperbalance shaft chain guide.

Tighten the upperbalance shaft chain guidebolts to 10 Nm (89 inchlbs.) .

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13/23

2. Install the small balance shaft chain guide.

3. Tighten thebalance shaft chain guidebolts.

Tighten the chain guide bolts to 10 Nm (89 inch lbs.) .

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14/23

4. Install the adjustable balance shaft drive chain guide.

Tighten the chain guide bolts to 10 Nm (89 inch lbs.) .

5. Turn the tensioner plunger90 degrees in its bore and compress the plungeruntil a paper clip can be inserted through the hole in the plunger body and intohole in the tensioner plunger.

6. Install the timing chain tensioner.

7. Tighten the chain tensioner bolts.

Tighten the chain tensioner bolts to 10 Nm (89 inch lbs.) .

8. Remove the paper clip from the balance shaft drive chain tensioner.

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15/23

9. Install the crankshaft sprocket with timing mark at the 5 o'clock position.

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16/23

10.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).

11. Install the intake camshaft sprocket with the INT diamond at the 2 o'clockposition.

12.Hand tighten a NEW intake camshaft sprocket bolt.

13. Route the timing chain around the crankshaft sprocket with the second silverlink aligning with the timing mark.

14. Route the timing chain around the intake camshaft sprocket with the coppercolored link (1) aligning with the INT diamond.

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17/23

15.Install the timing chain tensionerguide through the opening in the top of thecylinder head.

Tighten thetiming chain tensionerguide bolt to 10 Nm (89 inch lbs.) .

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18/23

16. Install the exhaust camshaft sprocket with the timing chain silver link (3) atEXH triangle aligned at the 10 o'clock position.

17.Use a 24 mm wrench to rotate the camshaftslightly, until exhaust sprocketaligns with the camshaft.

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19/23

18.Hand tighten the NEW exhaust camshaft sprocket bolt.

19.Install the fixed timing chain guide.

Tighten the fixed timing chain bolts to 10 Nm (89 inch lbs.) .

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20/23

20.Apply sealant, GM P/N 12345382 (Canadian P/N 10953489) compound tothread and install the timing chain guidebolt access hole plug.

Tighten the access hole plug to 40 Nm (30 ft. lbs.) .

21.Install the engine mount.

22.Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, orwasher is damaged, replace the timing chain tensioner.

23.Measure thetiming chain tensionerassembly 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 inch) (a) from end to end. A

tensioner in the active state will measure 85 mm (3.35 inch) (a) from end toend.

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24.If the timing chain tensioneris not in the compressed state, perform the followingsteps:

24.1. Remove the piston assembly from the body of the timing chain tensionerby

pulling it out.24.2. Install the J 45027-2 (2) into a vise.

24.3. Install the notch end of thepiston assembly into the J 45027-2 (2).

24.4. Using the J 45027-1 (1), turn the ratchet cylinder into thepiston.

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25.Inspect the bore of the tensioner body for dirt, debris, and damage. If anydamage appears, replace the tensioner. Clean dirt or debris out with a lint freecloth.

26.Install the compressed piston assembly back into the timing chain tensionerbodyuntil 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 bereset again.

27.At this point the tensioner should measure approximately 72 mm (2.83 inch)

(a) from end to end. If the tensioner does not read 72 mm (2.83 inch) (a) fromend to end repeat steps 16.1 and 16.4.

28.Inspect to ensure all dirt and debris is removed from the timing chain tensionerthreaded hole in the cylinder head.

29.Install the new timing chain tensionerassembly.

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Tighten thetiming chain tensionerto 75 Nm (55 ft. lbs.) .

30.The timing chain tensioneris released by compressing it 2 mm (0.079 inch)which will release the locking mechanism in the ratchet. To release the timingchain tensioner, use a suitable tool with a rubber tip on the end. Feed the tooldown through the cam drive chest to rest on the cam chain. Then give a sharp

jolt diagonally downwards to release the tensioner.

31.Use a 24 mm wrench to hold the camshaft.

Tighten the NEW camshaftbolts to 85 Nm (63 ft. lbs.) plus 30 degrees .

32. Install the camshaft cover.

33. Raise the vehicle.

34. Install the engine front cover.

35. Lower the vehicle.

36. Connect negative battery cable.

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04 sun fire timing

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