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. Install engine support fixture - J 28467-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 (8 mm drill, 1/2 inch deep).
CAUTION: Wear safety planes 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 failing 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 turns and remove chips.
30. Center punch and drill (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.
31. Enlarge pilot holes with 5.5 mm drill; 1/4 inch deep.
32. Tap 5.5 mm holes with 1/4-28-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 in.lbs.).
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 Calaas
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.