GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2007 🢒 Epica 🢒 Engine 🢒 Engine Mechanical - 2.0L and 2.5L 🢒 Camshaft Timing Chain and Sprocket Replacement

Tools Required
    • EN 47519 , DW117 (DW110-060) Universal Engine Support Fixture
    • J 39580 (DW010-010) Power Pack Stand Engine and Transaxle Assembly Support Remover/Installer
    • OTC 1726 (DW110-030) Engine Overhaul Stand
    • EN-47610 (DW110-130-01) Crankshaft Pulley Holder
    • EN-47611 (DW110-130-02) Crankshaft Pulley Installer/Remover
    • EN-47612 (DW110-140) Timing Chain Cover Install Guide Pin
    • EN-47613 (DW110-150) Camshaft Sprocket Holder
    • EN-47617 (DW110-190) Crankshaft Adjuster

Removal Procedure

    Object Number: 1375807 Size: SH
  1. Remove the fuel pump fuse.
  2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.

    3. Caution: Refer to Battery Disconnect Caution in the Preface section.

  3. Disconnect the negative battery cable.
  4. Drain the engine coolant. Refer to Cooling System Draining and Filling .
  5. Drain the engine oil.
  6. Drain the transaxle oil.

    7. Object Number: 1375772 Size: SH
  7. Drain the power steering oil.
  8. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  9. Remove the engine assembly using the J 39580  (1). Refer to Engine Replacement .

    10. Object Number: 1375809 Size: SH
  10. Remove the flexible plate bolts and the flexible plate.
  11. Support the engine assembly with the OTC 1726 .

    12. Object Number: 1375152 Size: SH
  12. Remove the intake manifold. Refer to Intake Manifold Replacement .

    13. Object Number: 1375565 Size: SH
  13. Remove the cylinder head cover. Refer to Cylinder Head Cover Replacement .

    14. Object Number: 1375810 Size: SH
  14. Remove the drive belt.

    15. Object Number: 1375584 Size: SH
  15. Remove the oil pan. Refer to Oil Pan Replacement .

    16. Object Number: 1375811 Size: SH

    Important: Very high torque is required to remove or to install the crankshaft pulley. Never remove the crankshaft pulley when the vehicle is hung on the lift.

  16. Install the EN-47610  (1) to the crankshaft pulley bolt.

    17. Object Number: 1375813 Size: SH
  17. Remove the crankshaft pulley bolt using the EN-47611  (2).

    18. Object Number: 1375816 Size: SH
  18. Remove the engine mount bracket support.

    19. Object Number: 1375881 Size: SH
  19. Remove the water pump pulley.

    20. Object Number: 1375885 Size: SH
  20. Remove the drive belt automatic tensioner retaining bolts and the tensioner.

    21. Object Number: 1375888 Size: SH
  21. Remove the timing chain cover.
  22. Remove 2 dowel rings for timing cover.

    23. Object Number: 1375890 Size: SH
  23. Remove the timing chain tensioner.

    24. Object Number: 1375893 Size: SH
  24. Remove the fixed timing chain guide.

    25. Object Number: 1375895 Size: SH
  25. Remove the timing chain lever.

    26. Object Number: 1375896 Size: SH
  26. Remove the top chain guide.
  27. Remove the timing chain.
  28. Remove the crankshaft sprocket and the woodruff key.

Installation Procedure

    Object Number: 1375900 Size: SH
  1. Install the crankshaft sprocket and the woodruff key.
  2. Install the timing chain after aligning both the mark on the camshaft sprocket and on the timing chain using the EN-47613  (1).

    3. Object Number: 1375904 Size: SH
  3. Align both the timing mark on the crankshaft sprocket and on the timing chain.
  4. Adjust the crankshaft using the EN-47617  (1).

    5. Object Number: 1375905 Size: SH
  5. Make sure the 3 timing marks on the timing chain are exactly aligned with the marks on the exhaust camshaft sprocket, intake camshaft sprocket, ant crankshaft sprocket respectively.

    6. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1375908 Size: SH
  6. Install the fixed timing chain guide.

    7. Tighten
    Tighten the fixed timing chain guide bolts to 20 N·m (15 lb ft).


    Object Number: 1375910 Size: SH
  7. Install the timing chain lever.

    8. Tighten
    Tighten the timing chain lever bolt to 20 N·m (15 lb ft).


    Object Number: 1375913 Size: SH
  8. Install the timing chain tensioner.

    9. Tighten
    Tighten the timing chain tensioner bolt to 20 N·m (15 lb ft).


    Object Number: 1375915 Size: SH
  9. Install the top chain guide.

    10. Tighten
    Tighten the top chain guide bolt to 10 N·m (89 lb in).


    Object Number: 1375917 Size: SH
  10. Install 2 dowel rings.
  11. Apply the liquid gasket Loctite® 5900-M8585 on the timing chain cover.

    12. Object Number: 1375918 Size: SH

    Important: Be sure the applied liquid gasket is not damaged when installing the timing chain cover.

  12. Install the EN-47612  (1) and position the timing chain cover.

    13. Object Number: 1375919 Size: SH
  13. Install the timing chain cover.

    14. Tighten

        • Tighten the timing chain cover center bolt to 20 N·m (15 lb ft).
        • Tighten the timing chain cover bolts to 8 N·m (71 lb in).

    Object Number: 1375921 Size: SH
  14. Install the drive belt automatic tensioner.

    15. Tighten
    Tighten the drive belt automatic tensioner retaining bolt to 25 N·m (18 lb ft).


    Object Number: 1375924 Size: SH
  15. Install the water pump pulley.

    16. Tighten
    Tighten the water pump pulley bolts to 10 N·m (89 lb in).


    Object Number: 1375929 Size: SH
  16. Install the engine mount bracket support.

    17. Tighten
    Tighten the engine mount bracket support bolts to 28 N·m (21 lb ft).


    Object Number: 1375946 Size: SH
  17. Install the crankshaft pulley. Tighten the crankshaft pulley bolt using the EN-47610  (1) and the EN-47611  (2).

    18. Tighten
    Tighten the crankshaft pulley bolt to 550 N·m (406 lb ft).


    Object Number: 1375622 Size: SH
  18. Install the oil pan. Refer to Oil Pan Replacement .

    19. Object Number: 1375566 Size: SH
  19. Install the cylinder head cover. Refer to Cylinder Head Cover Replacement .
  20. Install the drive belt.

    21. Object Number: 1375572 Size: SH
  21. Install the intake manifold. Refer to Intake Manifold Replacement .

    22. Object Number: 1375963 Size: SH
  22. Install the flexible plate.

    23. Tighten
    Tighten the flexible plate bolts to 75 N·m (55 lb ft).


    Object Number: 1375772 Size: SH
  23. Mount the engine on the J 39580  (1).
  24. Install the transaxle to the engine assembly.
  25. Install the engine and transaxle assembly. Refer to Engine Replacement .
  26. Install the fuel pump fuse.
  27. Connect the negative battery cable.
  28. Refill the crankcase with engine oil.
  29. Refill the engine coolant system. Refer to Cooling System Draining and Filling .
  30. Fill and bleed the power steering system. Refer to Power Steering System Bleeding .
  31. Refill the A/C system. Refer to Refrigerant Recovery and Recharging .