Chevrolet Cobalt Service & Repair Manual: Timing Chain Tensioner R & R

1. Disconnect the negative battery cable.
2. Remove the camshaft cover.
3. Remove the timing chain tensioner, Fig. 1.
4. Remove the seal from the tensioner.
5. Reverse procedure to install, noting the following:
  a. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
  b. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 2.83 inch (a) from end to end. A tensioner in the active state will measure 3.35 inch (a) from end to end.
  c. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install tool No. J-45027-2 (2) into a vise, then install the notch end of the piston assembly into tool No. J-45027-2 (2). Using tool No. J-45027-1 (1), turn the ratchet cylinder into the piston, Fig. 2.
  d. Torque timing chain tensioner to 55 ft. lbs.
  e. Torque camshaft cover and bolts to 89 inch lbs.

Fig. 1 Timing chain tensioner replacement

Fig. 2 Timing chain tensioner Installation

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    Caution: With the timing chain removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact. ...

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