GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 Prizm 🢒 Engine 🢒 Engine Controls - 1.8L 🢒 Camshaft Timing Chain and Sprocket Replacement

Removal Procedure

    Object Number: 244267 Size: SH

    Important: When performing any service procedure that pertains to the camshaft or the camshaft actuator, unlock the camshaft actuator locking pin. Refer to Camshaft Position Actuator Locking Pin Adjustment .

  1. Remove the accessory drive belt. Refer to Drive Belt Replacement .
  2. Remove the generator from the engine. Refer to Generator Replacement in Engine Electrical.

    3. 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.

  3. Disconnect the negative battery cable.
  4. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  5. Remove the windshield washer fluid reservoir mounting bolt.
  6. Disconnect the windshield washer pump connector.
  7. Disconnect the windshield washer pump fluid line.
  8. Plug the pump outlet
  9. Remove the windshield washer fluid reservoir.
  10. Install the engine support fixture. Refer to Engine Support Fixture .

    11. Object Number: 234412 Size: SH
  11. Remove the following fasteners from the right side engine mount:
    12. • The 2 nuts (3)
    • The 4 bolts (1)
  12. Loosen the A/C receiver pinch clamp.
  13. Lift the A/C receiver in order to access the right side engine mount.
  14. Remove the right side engine mount.
  15. Remove the cylinder head cover. Refer to Cylinder Head Cover Replacement .

    16. Object Number: 234138 Size: SH
  16. Set the number one piston to the top dead center position.
  17. Align the camshaft timing sprockets.
  18. Disconnect the power steering oil pressure switch connector.
  19. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  20. Remove the right side lower engine splash shield.

    21. Object Number: 236875 Size: SH
  21. Remove the two power steering pump through bolts and the nuts (1).
  22. Remove the power steering pump from the mounting surface.

    23. Move the pump to the side.


    Object Number: 234153 Size: SH
  23. Remove the crankshaft pulley retaining bolt using J 8614-01 to prevent crankshaft rotation when loosening the bolt.
  24. Remove the crankshaft pulley.

    25. Object Number: 234378 Size: SH
  25. Remove the following components:
    26. • The crankshaft position sensor bolt (5)
    • The sensor
  26. Lower the vehicle.
  27. Remove the following components from the mounting surface:
    28. • The drive belt tensioner bolt
    • The drive belt tensioner nut
    • The drive belt tensioner

    Object Number: 234178 Size: SH
  28. Remove the timing chain tensioner bolts (1,2).
  29. Remove the timing chain tensioner.

    30. Object Number: 234182 Size: SH
  30. Remove the following fasteners:
    31. • The timing chain cover bolts (1-14)
    • The timing chain cover nut (15)
  31. Remove the timing chain cover.

    32. Object Number: 234359 Size: SH
  32. Remove the crankshaft sensor reluctor (1).

    33. Object Number: 625486 Size: SH
  33. Remove the following components:
    34. • The timing chain dampener bolt (1)
    • The timing chain dampener
    • The timing chain shoe bolts (2)
    • The timing chain shoe

    Object Number: 234188 Size: SH
  34. Remove the following components:
    35. • The crankshaft sprocket
    • The timing chain
  35. Remove the three bolts from the front camshaft bearing cap.
  36. Remove the front camshaft bearing cap in order to access the oil passage to the CMP actuator.

    37. Object Number: 652440 Size: SH
  37. Ensure that the CMP actuator will not turn.
  38. Apply air pressure of approximately 100 kPa (14 psi) to the advance passage of the camshaft.
  39. Turn the CMP actuator to the advanced angle side by hand.
  40. Rotate the actuator back and forth through the advanced positions to ensure 21 degrees of movement.
  41. Remove the air pressure and turn the CMP actuator back to the minimum advanced angle position to lock it.
  42. Replace the CMP actuator if the following conditions exist:
    43. • CMP actuator does not lock with air pressure removed.
    • CMP actuator does not unlock with air pressure applied.
    • CMP actuator does not rotate smoothly through the advanced positions.
    • CMP actuator does not rotate completely through the advance positions.
  43. Install the front camshaft bearing cap.

    44. 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.

  44. Install the front camshaft bearing cap bolts.

    45. Tighten
    Tighten the camshaft bearing cap bolts to 23 N·m (17 lb ft).

Installation Procedure

    Object Number: 625497 Size: SH
  1. Use a wrench in order to align the camshaft timing marks.

    2. Be sure to place the wrench on the hexagonal portion of the camshafts.


    Object Number: 625505 Size: SH
  2. Turn the camshafts in order to align the timing marks.

    3. Object Number: 234304 Size: SH
  3. Temporarily install the crankshaft bolt.
  4. Turn the crankshaft until the crankshaft keyway (1) faces upward.

    5. Object Number: 881599 Size: SH
  5. Install the following components:
    6. • The timing chain (2)
    • The crankshaft timing sprocket

    Object Number: 234315 Size: SH

    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.

  6. Install the timing chain shoe. Secure the timing chain shoe using two bolts (1,2).

    7. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1696396 Size: SH
  7. Install the timing chain (1) onto the exhaust camshaft sprocket  (4) and the intake camshaft sprockets (5).

    8. Ensure that the timing chain links  (2) are aligned with the timing marks (3). The intake cam phaser mark  (7) should be at the 9 o'clock position and the "Ex" timing mark  (8) on the exhaust camshaft sprocket  (4) should be at the 3 o'clock position. The colored links (2) will line up around the 12 o'clock position with the double dots  (3) on the exhaust sprocket and the line  (6) on the cam phaser body.


    Object Number: 625486 Size: SH
  8. Install the timing chain dampener. Secure the timing chain dampener using one bolt (1).

    9. Tighten
    Tighten the bolt to 18 N·m (14 lb ft).


    Object Number: 234359 Size: SH
  9. Install the crankshaft sensor reluctor (1) onto the crankshaft. Insure that the letter "F" on the reluctor is facing outward.
  10. Apply a continuous bead of GM P/N 12346240 or an equivalent to the timing chain cover mating surface.
  11. Unlock the intake camshaft actuator locking pin. Refer to Camshaft Position Actuator Locking Pin Adjustment .

    12. Object Number: 234375 Size: MH
  12. Install the timing chain cover.

    13. Use the following fasteners in order to secure the cover:

    • Fifteen bolts (1-14)
    • One nut (15)

    Tighten

       • 

    Tighten the timing chain cover nut and bolts (10 mm (0.394 in) head) to 10 N·m (89 lb in).

       • 

    Tighten the timing chain cover nut and bolts (12 mm (0.394 in) head) to 18 N·m (14 lb ft).


    Object Number: 234392 Size: SH
  13. Use the following steps in order to install the timing chain tensioner:
    14. 13.1. Fully depress the plunger (4).
    13.2. Apply the hook (2) to the pin (3).
    13.3. Install the timing chain tensioner.

    Object Number: 234394 Size: SH
  14. Install the timing chain tensioner. Secure the timing chain tensioner using 2 bolts (1).

    15. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 234378 Size: SH
  15. Install the right side engine mounting bracket. Secure the bracket using 3 bolts.

    16. Tighten
    Tighten the bolts to 54 N·m (40 lb ft).

  16. Install the drive belt tensioner. Secure the tensioner using one bolt and one nut.

    17. Tighten

        • Tighten the bolt to 69 N·m (51 lb ft).
        • Tighten the nut to 29 N·m (21 lb ft).
  17. Raise the vehicle. Support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  18. Install the crankshaft position sensor. Secure the sensor using one bolt (5).

    19. Tighten
    Tighten the bolt to 12 N·m (106 lb in).


    Object Number: 234382 Size: SH
  19. Install the crankshaft pulley. Secure the crankshaft pulley using one bolt.

    20. Tighten
    Tighten the crankshaft pulley to 142 N·m (105 lb ft).


    Object Number: 236875 Size: SH
  20. Install the power steering pump.
  21. Use the following fasteners in order to secure the power steering pump:
    22. • 2 bolts (1)
    • 2 nuts

    Tighten
    Tighten the bolts to 37 N·m (27 lb ft).

  22. Install the right side lower engine splash shield.
  23. Lower the vehicle.
  24. Connect the power steering oil pressure switch connector.

    25. Object Number: 234400 Size: SH
  25. Rotate the crankshaft clockwise one revolution. Ensure that the plunger on the timing chain tensioner has released.

    26. Complete the following steps if the plunger does not release:

    • Use a screwdriver or your finger in order to press the timing chain dampener into the timing chain tensioner.
    • Release the hook from the pin.
    • Verify proper timing chain alignment after the plunger has released.
  26. Install the cylinder head cover.

    27. Object Number: 234412 Size: SH
  27. Install the right side engine mount.
  28. Use the following fasteners in order to secure the mount:
    29. • 3 bolts (1)
    • 2 nuts (3)

    Tighten

       • 

    Tighten the right side engine mount bolts (1,2,4) to 54 N·m (40 lb ft).

       • 

    Tighten the right side engine insulator nuts (3) to 54 N·m (40 lb ft).

  29. Lower the A/C receiver.

    30. Tighten the pinch clamp.


    Object Number: 428195 Size: SH
  30. Remove the engine support fixture (J 28467-A).
  31. Install the generator. Refer to Generator Replacement in Engine Electrical.
  32. Remove the plug from the windshield washer reservoir.
  33. Connect the windshield washer fluid line.
  34. Connect the windshield washer pump connector.
  35. Install the windshield washer reservoir. Secure the reservoir using one bolt.
  36. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  37. Connect the negative battery cable.

    38. Tighten
    Tighten the cable bolt to 15 N·m (11 lb ft).