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Service Information
1998 Chevrolet Cavalier | Cavalier, Sunfire (VIN J) Service Manual | Engine | Engine Cooling | Repair Instructions | Document ID: 217207
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Timing Chain Housing Replacement
Removal Procedure
Tools Required
• J 24420-B Crankshaft Balancer Puller
• J 28467-360 Engine Support
• J 38122-A Crankshaft Balancer Holder
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
Important: The timing chain housing to cylinder block and the camshaft housing gaskets can be replaced without removing the timing chain housing from the vehicle.
Removal of the timing chain housing is only required when additional service is being performed on the timing chain housing.
Disconnect the negative battery cable.
Remove the engine front cover. Refer to Engine Front Cover Replacement .
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Disconnect the heater hose from the thermostat housing in order to drain the cylinder block completely.
Important: The timing chain must be marked prior to removal. If the chain is installed with the wear pattern in the opposite direction, noise and increased wear may occur.
Remove the timing chain tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement .
Remove the timing chain. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement .
Remove the coolant pump assembly to the timing chain housing nuts. Refer to Water Pump Replacement in Engine Cooling.
Remove the timing chain housing to the block fasteners.
Remove the four oil pan to front cover bolts.
Remove the lowest front cover retaining stud from the timing chain housing.
This stud will catch on the body if it is not removed.
Lower the vehicle.
Remove the camshaft sprocket retaining bolts and the washers while holding the sprockets with the J 38122-A .
Remove the camshaft sprockets.
The camshaft sprockets are identical and interchangeable.
Remove the chain housing to the camshaft housing bolts (1).
Remove the timing chain housing and the gaskets.
It may be necessary to raise the engine slightly using the J 28467-360 .
Inspect the oil pan gasket silicone bead for the following conditions:
• Cuts or nicks
• Deformation
• Separation from the aluminum carrier
If any of the conditions exist, replace the pan gasket.
Important: Use only enough sealant to restore the silicone bead to its original dimension. Excess application of sealant may cause part misalignment and oil leaks.
Inspect the silicone bead across the top of the aluminum carrier at the oil pan, in the cylinder block, and to the timing chain housing three way joint. Repair a damaged bead using the Silicone Rubber Sealant GM P/N 12345739 or the equivalent.
Installation Procedure
Prior to installing the timing chain housing, ensure that the alignment dowel pins are in the cylinder block and the timing chain housing. The dowel pins ensure proper chain housing and the front cover location for correct front oil seal-to-crankshaft alignment.
Install the timing chain housing and the new gaskets. Gasket sealer is unnecessary.
Important: Hand tighten all chain housing bolts before tightening to specifications.
Install the chain housing to the camshaft housing bolts and hand tighten.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Install the timing chain housing block fasteners and hand tighten.
Install the oil pan to the timing chain housing bolts and hand tighten.
Tighten the timing chain housing block fasteners.
Tighten
• (1) (M8 X 1.25 X 25) 26 N·m (19 lb ft).
• (2) (M8 X 1.55 X 55) 50 N·m (37 lb ft).
• (3) (M10 X 1.25 X 35) 29 N·m (21 lb ft).
Tighten the oil pan to the timing chain housing bolts.
Tighten
• (1) (M8 X 1.25 X 80) 24 N·m (18 lb ft).
• (2) (M8 X 1.24 X 22) 24 N·m (18 lb in).
• (3) (M6 X 1.00 X 25) 12 N·m (106 lb ft).
• (4) 26 N·m (19 lb ft).
Install the lowest front cover retaining stud into the timing chain housing.
Install the coolant pump to the timing chain housing and the timing chain housing nuts.
Tighten
Tighten the timing chain housing nuts to 26 N·m (19 lb ft).
Lower the vehicle.
Tighten the timing chain housing to the camshaft housing bolts.
Tighten
• (1) (M8 X 1.25 X 25) 26 N·m (19 lb ft).
• (2) (M10 X 1.55 X 55) 50 N·m (37 lb ft).
• (3) (M8 X 1.25 X 35) 29 N·m (21 lb ft).
Install the camshaft sprockets.
The camshaft sprockets are identical and interchangeable.
Install the camshaft sprocket bolts and the washers.
Tighten the camshaft sprocket bolts and the washers while holding the sprocket with the J 38122-A .
Tighten
Tighten the camshaft sprocket bolts to 70 N·m (52 lb ft).
Use the Adhesive/Sealant Compound GM P/N 12345493 or the equivalent on the camshaft sprocket bolts.
Clean the old sealant off of the bolt with a wire brush.
Clean the threaded hole in the camshaft with a round nylon brush.
Clean the threaded hole in the camshaft with a round nylon brush.
Important: The side of the timing chain that was marked during the removal must be showing when the chain is installed.
Install the timing chain and the tensioner. Refer to Camshaft Timing Chain, Sprocket, and Tensioner Replacement .
Install the front cover and the gaskets. Refer to Engine Front Cover Replacement .
Connect the negative battery cable.
© 2009 General Motors. All rights reserved. xTooltipElement
Service Information
1998 Chevrolet Cavalier | Cavalier, Sunfire (VIN J) Service Manual | Engine | Engine Cooling | Repair Instructions | Document ID: 1370933
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Camshaft Timing Chain, Sprocket, and Tensioner Replacement
Tools Required
• J 36008-A Camshaft Sprocket Alignment Pins
• J 39579 Camshaft Sprocket Wrench
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
Notice: The timing chain on the LD9 (VIN T) Twin Cam Engine is not to be replaced with the timing chain from any other model year. The timing sprockets are different on the Twin Cam engine and the shape of the links matches the sprockets. Engine damage may result if the wrong timing chain is used. The timing chain and the crankshaft sprocket must be marked so that they are reinstalled in the same side facing out at the time of reassembly.
Disconnect the negative battery cable.
Remove the engine front cover. Refer to Engine Front Cover Replacement .
Rotate the crankshaft clockwise (as viewed from the front of the engine, normal rotation) until the camshaft sprocket timing dowel pin holes align with the holes in the timing chain housing.
Set the crankshaft sprocket keyway pointing upwards. Align with the centerline of the cylinder bores. This is the timed position.
Remove the timing chain guides.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Ensure that all of the slack in the timing chain is above the tensioner assembly.
Remove the timing chain tensioner bolts and the tensioner.
Remove the tensioner shoe. Use a small locking ring plier in order to engage the hole in the locking tab and remove the shoe from the stud.
Notice: Do not attempt to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur.
Important: Mark the timing chain and the crankshaft sprocket prior to removal. If the chain or the crankshaft sprocket is installed with the wear pattern in the opposite direction, noise and increased wear may occur.
Mark the crankshaft sprocket and the timing chain outer surface.
Remove the timing chain.
Lower the vehicle.
Holding the intake camshaft sprocket with J 39579 , remove the sprocket bolt and washer.
Remove the washer from the bolt and rethread the bolt back into the camshaft.
Using a 3-jaw puller and the relief holes in the sprocket, remove the intake camshaft sprocket.
Repeat this procedure for the exhaust camshaft sprocket.
Clean the old sealant from the bolt with a wire brush.
Clean the threaded hole in the camshaft with a round nylon bristle brush.
Inspect the parts for wear. Replace the parts as necessary.
Some scoring of the timing chain shoe and the guides is normal.
Replace the timing chain shoe or guides if the scoring exceeds 1.12 mm (45 in).
Installation Procedure
Use Adhesive/Sealant Compound GM P/N 12345493 or equivalent on the camshaft sprocket bolt.
Install the intake and exhaust camshaft sprockets onto the camshafts with the marked surface showing.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Install the retaining bolts and washers to the intake and exhaust camshaft sprockets.
Tighten
Tighten the bolts to 70 N·m (52 lb ft) while holding the sprockets with the J 39579 .
Install the J 36800 through the holes in the camshaft sprockets into the holes in the timing chain housing. This will position the camshaft for correct timing.
If the camshafts are out of position (you must rotate the camshaft more than 1/8 turn in order to install the alignment dowel pins), use the following procedure:
4.1. Rotate the crankshaft 90 degrees clockwise off of the TDC in order to give the valves adequate clearance to open.
4.2. Once the camshafts are in position and the dowels installed, rotate the crankshaft counter clockwise back to the top dead center.
Notice: Do not rotate the crankshaft clockwise to TDC. Valve or piston damage could occur.
Important: The side of the timing chain that was marked during removal must be showing when the chain is installed.
Install the timing chain over the exhaust camshaft sprocket, around the coolant pump, and around the crankshaft sprocket.
5.1. Remove the alignment dowel pin from the intake camshaft.
5.2. Using the J 39579 , rotate the intake camshaft sprocket counterclockwise enough in order to slide the timing chain over the intake camshaft sprocket.
5.3. Release the J 39579 . The length of the chain between the 2 camshaft sprockets will tighten.
5.4. If properly timed the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated.
Leave the alignment dowel pins installed.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
The timing marks on the crankshaft and on the cylinder block should be aligned when the slack is removed from the chain linking the intake camshaft sprocket and the crankshaft sprocket. If the marks are not aligned, move the chain one tooth forward or rearward, remove the slack and re-examine the marks.
Important: Use the following steps in order to reset the timing chain tensioner assembly to the zero position.
Reset the timing chain tensioner assembly.
9.1. Insert the tensioner plunger assembly into the tensioner housing.
9.2. With the tensioner plunger fully extended, turn the complete assembly upside down on a bench or other flat surface.
9.3. With the plunger face against the workbench, press firmly on the bottom of the tensioner housing.
9.4. Compress the plunger until the plunger is seated flush in the tensioner.
Check the plunger to make sure the plunger is out of the cylinder at the correct dimension. The correct dimension for the plunger to extend out of the cylinder is 1.7 mm (0.07 in) maximum.
Loosely install the tensioner assembly and bolts to the timing chain housing.
Install the timing chain tensioner shoe on the stud.
Apply hand pressure to the timing chain tensioner shoe until the locking tab seats in the groove in the stud.
Tighten the timing chain tensioner bolts. Do Not overtighten.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
Important: If the timing chain tensioner is not released from the installation position, engine damage will occur when the engine is started.
Release the timing chain tensioner plunger.
15.1. Using a flat blade screwdriver, cotter pin remover, or similar tool, press firmly against the face of the timing chain tensioner plunger.
Important: If the timing chain tensioner cannot be depressed, the plunger is not properly reset and the procedure for resetting the timing chain tensioner should be repeated.
15.2. Depress the timing chain tensioner plunger until the plunger is bottomed out in the bore of the timing chain tensioner.
15.3. Release the tensioner plunger. the plunger should press firmly against the back of the timing chain tensioner shoe.
Remove J 36800 from the camshaft sprockets.
Rotate the crankshaft clockwise 2 full rotations. Align the crankshaft keyway with the mark on the cylinder block, and reinstall the alignment dowel pins. The pins should slide in easily if the engine is timed correctly.
Install the timing chain guides.
Install the engine front cover. Refer to Engine Front Cover Replacement .
Connect the negative battery cable.
Tighten
Tighten the bolt to 16 N·m (12 lb ft).
© 2009 General Motors. All rights reserved. xTooltipElement
Service Information
1998 Chevrolet Cavalier | Cavalier, Sunfire (VIN J) Service Manual | Engine | Engine Cooling | Repair Instructions | Document ID: 200170
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Water Pump Replacement (2.4L)
Removal Procedure
Notice: When adding coolant, use DEX-COOL® coolant. If silicated coolant is added to the system, premature engine, heater core or radiator corrosion may result. In addition, the engine coolant will require change sooner-at 50 000 km (30,000 mi) or 24 months.
Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power (RAP) should be allowed to time out or be disabled (simply opening the driver door should disable RAP) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition is On or with RAP activated may cause activation of the OnStar® Back-Up Battery (BUB) system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The BUB is not rechargeable and once activated the BUB must be replaced.
Disconnect the negative battery cable.
Drain the coolant. Recover the coolant. Refer to Cooling System Draining and Filling .
Disconnect the oxygen sensor (O2S) connector. Refer to Throttle Position Sensor Replacement in Engine Controls-2.2L or Throttle Position Sensor Replacement in Engine Controls-2.4L.
Remove the upper exhaust manifold heat shield. Refer to Exhaust Manifold Replacement in Engine Mechanical-2.2L or Exhaust Manifold Replacement in Engine Mechanical-2.4L.
Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Remove the exhaust manifold brace to manifold bolt.
Break loose the manifold to exhaust pipe bolts.
Remove the radiator outlet pipe assembly to coolant pump cover (2) bolts (1).
Notice: Do not rotate the flex coupling more than 4 degrees. Damage to the flex coupling may occur.
Remove the exhaust manifold pipe from the exhaust manifold. Pull down and back on the exhaust manifold pipe in order to disengage the pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine Mechanical-2.2L or Exhaust Manifold Replacement in Engine Mechanical-2.4L.
Remove the radiator outlet pipe (1) from the oil pan (2).
• With a manual transaxle, remove the exhaust manifold brace.
• Keep the radiator inlet hose attached. Pull down on the radiator outlet pipe in order to disengage the pipe from the coolant pump. Leave the radiator outlet pipe hanging.
Lower the vehicle.
Remove the following parts in order:
12.1. The brake vacuum pipe from the cam housing
12.2. The exhaust manifold to cylinder head retaining nuts
12.3. The exhaust manifold
12.4. The seals and gaskets of the exhaust manifold, refer to Exhaust Manifold Replacement in Engine Mechanical-2.2L or Exhaust Manifold Replacement in Engine Mechanical-2.4L.
Remove the front timing chain cover. Refer to Timing Chain Housing Replacement in Engine Mechanical-2.4L.
Remove the timing chain tensioner. Refer to Timing Chain Housing Replacement in Engine Mechanical-2.4L.
Remove the coolant pump cover to cylinder block bolts.
Remove the coolant pump to timing chain housing nuts.
Remove the coolant pump cover (3) and the coolant pump (2) and the gaskets (1).
Remove the coolant pump cover to coolant pump assembly bolts (4).
Clean all sealing surfaces.
Installation Procedure
Important: Before you install the coolant pump, read the entire procedure. Pay special attention to the tightening sequences in order to avoid part damage and to provide proper sealing.
Install the coolant pump cover (3) and the gasket (1) to the coolant pump (2).
1.1. Lubricate the splines of the coolant pump drive with Chassis Grease GM P/N 1051344, or equivalent.
1.2. Install the coolant pump cover to coolant pump bolts (4), then hand tighten the bolts.
Install the coolant pump and the coolant pump cover assembly in position on the engine block.
Install the coolant pump cover to block bolts. Hand tighten the bolts.
Install the coolant pump to timing chain housing nuts. Hand tighten the nuts.
Lubricate the O-ring on the radiator outlet pipe with an antifreeze solution.
5.1. Slide the outlet pipe into the coolant pump cover.
5.2. Install the bolts. Hand tighten the bolts.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten the coolant pump assembly to timing chain housing nuts.
Tighten
Tighten the nuts to 26 N·m (19 lb ft).
Tighten the coolant pump cover to water pump bolts (4).
Tighten
Tighten the bolts to 14 N·m (124 lb in).
Tighten the coolant pump cover to engine block bolts.
Tighten
Tighten the bottom bolt first. Tighten the bolts to 26 N·m (19 lb ft).
Tighten the radiator outlet pipe to coolant pump cover (2) bolts (1).
Tighten
Tighten the bolts to 14 N·m (124 lb in).
Using new gaskets, install the exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence and tighten to specification. Refer to Exhaust Manifold Replacement in Engine Mechanical-2.2L or Exhaust Manifold Replacement in Engine Mechanical-2.4L.
Connect the brake vacuum pipe to the cam housing.
Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Index the exhaust manifold bolts into the exhaust pipe flange.
Install the exhaust pipe to the exhaust manifold and the bolts. Turn both bolts in evenly in order to avoid cocking the exhaust pipe and binding the bolts. Turn in the bolts until the bolts are fully seated. Refer to Exhaust Manifold Replacement in Engine Mechanical-2.2L or Exhaust Manifold Replacement in Engine Mechanical-2.4L.
Install the heater outlet pipe bracket to the transmission.
Install the radiator outlet pipe (1) to the oil pan (2). Install the bolts. With a manual transaxle, install the exhaust manifold brace.
Tighten
Tighten the outlet pipe to oil pan bolt to 25 N·m (18 lb ft).
Install the timing chain tensioner. Refer to Timing Chain Housing Replacement in Engine Mechanical-2.4L.
Install the timing chain cover. Refer to Timing Chain Housing Replacement in Engine Mechanical-2.4L.
Lower the vehicle.
Install the exhaust manifold brace to manifold bolt.
Tighten the manifold to exhaust pipe nuts to specification.
Install the exhaust manifold upper heat shield.
Connect the oxygen sensor (O2S) connector. Refer to Throttle Position Sensor Replacement in Engine Controls-2.2L or Throttle Position Sensor Replacement in Engine Controls-2.4L.
Fill the radiator with coolant until the coolant level reaches the heater hose coolant outlet. Then install the hose (this action assists in a complete cylinder block fill). Continue the filling procedure. Refer to Cooling System Draining and Filling .
Connect the negative battery cable.
Tighten
Tighten the negative battery cable bolt to 15 N·m (11 lb ft).
Start the engine. After the engine reaches normal operating temperature, inspect for coolant leaks.
© 2009 General Motors. All rights reserved.
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