For 1990-2009 cars

# SERVICE MANUAL UPDATE-REVISED CAM GEAR REPLACEMENT PROCEDURE

1982-88 CUTLASS CIERA AND 1985-88 CALAIS MODELS EQUIPPED WITH 2.5L ENGINE (VIN CODE R AND U)

This bulletin supersedes current and past service manual procedures. This bulletin also supersedes the December 1986 Service Guild article on this subject.

Revised service procedures have been developed for replacement of camshaft timing gears. The revised procedures do not require the complete removal of the engine from the vehicle. Cam gear replacement is generally accomplished by partially lowering the engine/frame assembly to gain access to the cam gear.

This bulletin contains two separate and complete procedures for servicing cam gears on subject models.

#### NOTICE: See appropriate service manual section for fastener torque specifications.

#### CUTLASS CIERA SERVICE PROCEDURE

#### Tools Required:

J 28467-A Engine Support Fixture J 24420-B Cam Gear Removal Tool J 25033-B or Cam Gear Installation Tool BT-7005A J 34995 Crankshaft Front Cover Oil Seal Installer J 8001 Universal Dial Indicator with Magnetic Base

#### Remove or Disconnect

1. Negative battery cable.

2. Drain coolant.

3. Belt tensioner and belt, or drive belts as applicable.

4. Upper engine torque strut.

5. Timing pointer plate (as applicable).

6. Both forward hood bumpers.

7. Install engine support fixture - J 28467-A per service manual.

8. Raise vehicle.

9. Both front wheels.

10. Drain engine oil (remove oil filter).

11. Steering shaft pinch bolt at steering gear.

12. Right front lower ball joint.

13. Right front brake line-to-body bracket.

14. Right front wheelhouse engine splash shield.

15. Flywheel cover.

16. Crankshaft pulley (have assistant hold flywheel).

17. Frame bolts and insulators (4).

18. Lower vehicle.

19. Timing gear cover bolts (8).

20. Lower the passenger side of the frame/powertrain assembly 4 inches with support fixture (may require lowering of driver's side).

21. Raise vehicle.

22. Timing gear cover-do not distort.

Clean

- Timing gear cover and engine sealing surfaces.

23. Align crankshaft/camshaft timing marks on gears.

24. Drill and tap hole on the camshaft centerline (8mm drill, 1/2inch deep).

#### CAUTION:

Wear safety glasses to avoid eye damage.

#### IMPORTANT: Use care when drilling and tapping cam gear to avoid damage to the camshaft. Cover oil pan opening with rags to prevent chips from falling into pan.

25. Tap the 8 mm hole with a 3/8-16-NC bottoming tap.

#### IMPORTANT: Avoid buildup of chips. Back out the tap every few turns and remove chips.

26. Center punch and drill two (2) 3 mm pilot holes in the metal hub of the cam gear (180 degrees apart).

#### IMPORTANT: Use care to avoid drill wander that could damage camshaft. Enlarge pilot holes with 5.5 mm drill; 1/4 inch deep.

28. Tap 5.5 mm holes with l/4-28-NF bottoming tap.

29. Drill a hole no larger than 1 mm (.040 inch) in the front oil gallery plug. This provides improved lubrication to the timing gears.

Clean

- Oil pan sealing surface of debris.

30. Cam gear with J 2"20-B. Do not move cam or crank.

Inspect

- Thrust plate for scuffing and/or grooving. If evident, install new thrust plate, spacer ring, and key.

Thrust plate-to-block bolts torque - 10 N -m (90 lbs. in.).

#### IMPORTANT: Lubricate front thrust plate surface with clean engine oil.

#### Install or Connect

1. Cam gear using J 25033-B - align timing marks.

Measure

- Camshaft end play using dial indicator - J 8001 or equivalent. Push cam gear onto camshaft until camshaft end play is in the range of .04 mm to .13 mm (.0015 in. to .0050 inch).

2. J 34995 into front cover - lubricate seal lip with clean engine oil.

3. Apply RTV sealant to timing gear cover sealing surfaces.

4. Timing gear cover to engine.

5. Brake line bracket to frame.

6. Crank pulley and bolt.

7. Flywheel cover and bolts.

8. Lower vehicle.

9. Raise frame assembly with support fixture.

10. Install (4) frame bolts finger tight.

11. Remove engine fixture.

12. Raise vehicle.

13. Tighten frame bolts.

14. Lower ball joint; use new pinch bolt.

15. Steering shaft pinch bolt.

16. Engine splash shield.

17. Both front wheels.

18. Lower vehicle.

19. Front hood bumpers

20. Engine torque strut.

21. Tensioner-as applicable.

Clean

- Tensioner and block sealing surfaces. Do not remove sealing ring. Apply RTV around sealing ring.

22. Timing pointer plate (as applicable).

23. Accessory drive belt(s).

24. Engine oil (replace oil filter).

25. Coolant.

26. Negative battery cable.

27. Check front wheel toe-in and adjust if necessary.

Inspect

- For oil and .coolant leaks with engine running at operating temperature.

- For proper completion of repairs.

#### Warranty Information

1987-88 Cutlass Ciera

Labor Operation: J0840 Labor Time: 3.9 Hrs.

#### Add:

To Replace Crankshaft Gear .1 Hr. Locking Wheel Covers .2 Hr.

1982-86 Cutlass Ciera

Labor Time: 4.2 Hrs.

#### Add:

With A/C .1 Hr. To Replace Crankshaft Gear .1 Hr. Locking Wheel Cover .2 Hr.

CALAIS AND CUTLASS CALAIS SERVICE PROCEDURE

#### Tools Required:

J 28467-A Engine Support Fixture (with Long Hooks) J 24420-B Cam Gear Removal Tool J 25033-B Cam Gear Installation Tool J 34995 Crankshaft Front Cover Oil Seal Installer J 8001 Universal Dial Indicator with Magnetic Base

Remove or Disconnect

1. Negative battery cable.

2. Accessory drive belts.

3. Power steering pump mount bolts - lay pump aside.

4. Drain coolant(1985-86 ONLY).

5. Timing pointer plate (1985-86 ONLY).

6. Body ground strap.

7. Front end sheet metal diagonal brace (R.H.).

8. lnstall engine support fixture -J28467- A per service manual.

9. Upper front engine mount-to-body bolts (2).

10. Raise vehicle.

11. Right front wheel.

12. Right front brake line-to-body bracket.

13. Right front wheelhouse engine splash shield.

14. Flywheel cover.

15. Crankshaft pulley (have assistant hold flywheel).

16. Rear engine mount-to-bracket nuts and mount through bolts.

17. Rear transaxle strut - automatic transaxle only (as applicable).

18. Lower front engine mount-to-body bolt (leave mount attached to engine).

19. Retaining bolts from right side front suspension support (6).

20. Retaining bolts from left side front suspension support (6).

21. Drain engine oil (remove oil filter).

22. Lower vehicle.

23. Transaxle mount through bolt.

24. Lower engine/transaxle assembly with engine support fixture.

25. Raise vehicle.

26. Timing gear cover - Do not distort.

Clean

- Timing gear cover and engine sealing surfaces.

27. Align crankshaft/camshaft timing marks on gears.

28. Drill and tap hole on the camshaft centerline (8mm drill, 1/2inch deep).

#### CAUTION:

Wear safety glasses to avoid eye damage.

#### IMPORTANT: Use care when drilling and tapping cam gear to avoid damage to the camshaft.

#### IMPORTANT: Cover oil pan opening with rags to prevent chips from falling into pan.

29. Tap the 8 mm hole with a 3/8-16-NC bottoming tap.

#### IMPORTANT: Avoid buildup of chips. Back out the tap every few turn; and remove chips.

30. Center punch and drill (2) 3 mm pilot holes in the metal 0512 hub of the cam gear (180 degrees apart).

#### IMPORTANT: Use care to avoid drill wander that could damage camshaft.

31. Enlarge pilot holes with 5.5 mm drill; 1/4 inch deep.

32. Tap 5.5 mm holes with l/4-28-NF bottoming tap.

33. Drill a hole no larger than 1 mm (.040 inch) in the front oil gallery plug. This provides improved lubrication to the timing gears.

Clean

- Oil pan sealing surface of debris.

34. Cam gear with J 24420-B - do not move cam or crank.

Inspect

- Thrust plate for scuffing and/or grooving. If evident, install new thrust plate, spacer ring, and key.

Thrust plate-to-block bolts torque - 10 N - m (90 1 bs. in.).

#### IMPORTANT: Lubricate front thrust plate surface with clean engine oil.

#### Install or Connect

1. Cam gear using J 25033-B - align timing marks.

Measure

- Camshaft end play using dial indicator - J 8001 or equivalent. Push cam gear onto camshaft until camshaft end play is in the range of .04 mm to .13 mm (.0015 inch to .0050 inch).

2. J 34995 into front cover - lubricate seal lip with clean engine oil.

3. Apply RTV sealant to timing gear cover sealing surfaces.

4. Timing gear cover to engine.

5. Lower vehicle.

6. Raise engine assembly with support fixture.

7. Through bolt in rear transaxle mount.

8. Retaining bolts (2) in front engine mount.

9. Raise vehicle.

10. Retaining nuts (2) and through bolts (2) in right front engine mount.

11. Retaining bolt (1) in left front engine mount.

12. Place axle stand under right front suspension support, raise into position and fasten with retaining bolts (6).

13. Place axle stand under left front suspension support, raise into position and fasten with retaining bolts.

14. Crankshaft pulley and bolt (with assistant).

15. Flywheel cover and bolts.

16. Engine splash shield.

17. Brake line-to-body bracket.

18. Right front wheel.

19. Lower vehicle.

20. Transaxle bracket to transaxle mount long bolt.

21. Remove engine support fixture.

22. Timing pointer plate (1985-86 ONLY).

23. Engine coolant (1985-86 ONLY).

24. Engine oil (replace oil filter).

25. Power steering pump mount bolts to engine.

26. Accessory drive belts.

27. Front end sheet metal diagonal brace (R. H.).

28. Body ground strap.

29. Negative battery cable.

30. Check front wheel toe-in and adjust if necessary.

Inspect

- For oil and coolant leaks with engine running at operating temperature.

- For proper completion of repairs.

#### Warranty Information

1987 Calais and 1988 Cutlass Calais

Labor Operation: J0840 Labor Time: 4.7 Hrs.

#### Add:

With A/C .2 Hr. To Replace Crankshaft Gear 1 Hr. Automatic Transaxle (1987 ONLY) .1 Hr. Locking Wheel Covers .1 Hr.

1985-86 Calias

Labor Time: 5.1 Hrs.

#### Add:

With A/C .2 Hr. To Replace Crankshaft Gear .1 Hr. Automatic Transaxle .1 Hr. Locking Wheel Covers .1 Hr.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.