Important: If the balance shafts are not properly timed to the engine, the engine may vibrate and make noise. TIMING & BALANCE SHAFT KIT INSTALLATION 1. Install the upper balance shaft chain guide. Tighten the upper balance shaft chain guide bolts to 15 Nm (133 inch lbs.) . GM & SATURN 2.2L

1. Install the upper balance shaft chain guide. Tighten the upper balance shaft chain guide bolts to 15 Nm (133 inch lbs.).

2. Install the small balance shaft chain guide.

3. Tighten the balance shaft chain guide bolts. Tighten the chain buide bolts to 10 Nm (89 inch lbs.).

Zoom Sized for Print

4. Install the adjustable balance shaft drive chain guide. Tighten the chain guide bolts to 2. Install the small 10balance Nm shaft (89 chain inch guide. lbs.) . 3. Tighten the balance shaft chain guide bolts. Tighten the chain guide bolts to 10 Zoom Sized for Print Nm (89 inch lbs.) .

4. Install the adjustable balance shaft drive chain guide. Tighten the chain guide bolts to 10 Nm (89 inch lbs.) .

5. Install the timing chain tensioner. Zoom Sized for Print 6. Tighten the chain tensioner bolts. Tighten the chain tensioner bolts to 10 Nm (89 inch

lbs.). 4. Install the adjustable balance shaft drive chain guide. Tighten the chain guide bolts to 10 Nm (89 inch lbs.) . 7. Remove the pin from the balance shaft 5. Turn the tensioner plunger 90 degrees in its bore and compress the plunger drive chain tensioner. until a paper clip can be inserted through the hole in the plunger body and into hole in the tensioner plunger. 6. Install the timing chain tensioner. 8. Install the oil nozzle and bolt.7. Tighten the chain the tensioner bolts. Tighten the chain tensioner bolts to 10 Nm (89 inch lbs.) . oil nozzle bolt to 10 Nm (89 lb in.)8. Remove. the paper clip from the balance shaft drive chain tensioner. 9. Install the oil nozzle and bolt. Tighten Tighten the oil nozzle blot to 10 Nm (89 lb in).

Zoom Sized for Print

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

Zoom Sized for Print

SA 76092

Zoom Sized for Print

10. Install the crankshaft sprocket with timing mark at the 5 o'clock position. 10. Lower the timing chain through the opening in the top of the cylinder head. CarefullyZoom ensure that theSized chain for Print goes around both sides of the cylinder block bosses. (1,2)

11. 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 block bosses (1, 2).

11.Zoom Install theS izedintake for Print camshaft sprocket with the INT diamond at the 2 o’clock position.

12. Hand tighten a NEW intake camshaft 11. Lower the timing chain through the opening in the top of the cylinder head. sprocketCarefully ensurebolt. that the chain goes around both sides of the cylinder block bosses (1, 2). 13. Route the timing chain around the crank-

shaftZoom sprocket withSized the for Printmatching color link align- ing with the timing mark.

14. Route the timing chain around the intake 12. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock camshaftposition. sprocket with the uniquely colored link 13.(1) Hand aligning tighten with a NEW the intake INT diamond. camshaft sprocket bolt. 14. Route the timing chain around the crankshaft sprocket with the matching color link aligning with the timing mark. 15. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.

15. Install the timing chain tensioner guide through the opening in the top of the cylinder head. Tighten the timing chain tensioner guide bolt to 10 Nm (89 inch lbs.).

Zoom Sized for Print

16. Install the exhaust camshaft sprocket with the

16. Install thetiming timing chain chain tensioner silver guide link through (3) at theEXH opening triangle in the aligned top of the at cylinder head.the 10Tighten o’clock the timingposition. chain tensioner guide bolt to 10 Nm (89 inch lbs.) .

SA 76092 Page 2

Zoom Sized for Print

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

Zoom Sized for Print Zoom Sized for Print

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

17. Use a 24 mm wrench to rotate the cam- shaft slightly, until exhaust sprocket aligns with the camshaft.

18. Hand tighten the NEW exhaust camshaft sprocket bolt.

18. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft. 19. Hand tighten the NEW exhaust camshaft sprocket bolt.

Zoom Sized for Print

19. Install the fixed timing chain guide. Tighten the fixed timing chain bolts to 15 Nm (133 inch lbs.).

Zoom Sized for Print 20. Verify that all the colored links are aligned Zoom Sized for Print with the appropriate exhaust (1), intake (2), and crankshaft marks (3). 20. Install the fixed timing chain guide. Tighten Tighten the fixed timing chain bolts to 15 Nm (133 inch lbs.) .

21. Verify that all the colored links are aligned with the appropriate exhaust (1), intake (2), and crankshaft marks (3).

Zoom Sized for Print

21. Apply sealant. GM P/N 12345382 (Canadian P/N 10953489) to thread and install the timing chain 21. Verify that all the colored links are aligned with the appropriate exhaust (1), guide bolt access holeintake plub. (2), and Tighten crankshaft marksthe access(3). hole plug to 90 Nm (66 foot lbs.).

SA 76092 Page 3 Zoom Sized for Print

22. apply sealant, GM P/N 12345382 (Canadian P/N 10953489) to thread and install the timing chain guide bolt access hole plug

Tighten Tighten the access hole plug to 90 Nm (66 lb ft).

23. Install the engine mount.

22. Measure the timing chain tensioner assembly from end to end. 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.) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in.) (a) from end to end.

Zoom Sized for Print

23. Inspect to ensure all dirt and debris is re- moved from the timing chain tensioner threaded 24. inspecthole thein thetiming cylinder chain tensioner head.. If the Install timing chainthe newtensioner, timing O-ring, or washerchain is tensioner damaged, replace assembly. the timing Tighten chain tension the er.timing chain 25. Measure the timing chain tensioner assembly from end to end. A new tensioner shouldtensioner be supplied to 75 in theNm fully (55 compressed ft. lbs.) .non-active state. A tensioner in the compressed state will measure 72 mm (2.83. in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.

Zoom Sized for Print 24. The timing chain tensioner is released by com- pressing 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 30. InspectZoom to ensure allSized dirt for and Print debris is removed from the timing chain tensioner on the end. Feedthreaded the toolhole indown the cylinder through head. the cam drive chest to rest31. on Install the thecam new chain. timing chain Then tensioner give assembly. a sharp Tighten jolt Tighten the timing chain tensioner to 75 Nm (55 ft. lbs.) . diagonally downwards32. The timing chain to release tensioner is thereleased tensioner. by compressing Use a it 2 mm (0.079 inch) 24 mm wrenchwhich to hold will release the camshaft. the locking mechanismTighten thein the NEW ratchet. To release the 33.timing Use chaina 24 mm tensioner, wrench useto hold a suitable the camshaft tool .with Tighten a rubber Tighten tip on the the NEW end. Feed camshaft bolt tothe camshaft85 tool Nm down bolts (63 through to 85ft. Nm lbs.)the (63 cam plusft. drivelbs.) 30 chestplus degrees. 30 to degrees. rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.

Zoom Sized for Print

25. Install the upper timing chain guide. Tight- en the upper guide bolts to 10 Nm (89 lb in). 33. Use a 24 mm wrench to hold the camshaft. Tighten Tighten the NEW camshaft bolts to 85 Nm (63 ft. lbs.) plus 30 degrees.

SA 76092 Page 4

Zoom Sized for Print

Zoom Sized for Print