Malfunction Indicator Lamp On - Check Engine Light, DTCs P0011, P0014, P0021, P0024, P0341, P0346, P0366 or P0391 Set (Check Camshaft End Play and Perform Action as Outlined)

This bulletin is being revised to provide an updated repair. Please discard Corporate Bulletin Number 08-06-01-011 (Section 06 -- Engine/Propulsion System).

Some customers may comment that the check engine light is on.

Upon investigation, the technician may find one or more of the following DTCs stored:

Camshaft End Play Measurement Procedure

Remove the camshaft cover from the suspect cylinder head.

Two methods for measuring camshaft end play:

Method 1: Dial Indicator

Notice: Do not use the phaser bolt as a pry point. This may cause damage to the camshaft sensor target wheel or the head to camshaft cover sealing surface.

Method 2: Caliper

The caliper should have 0.1 mm (.001") of resolution.

Camshaft Position Actuator to Front Camshaft Cap Measurement Procedure

Note: Before performing this procedure, inspect the rear of the camshaft position actuator. If there are five screws (Aisin Actuator) in the rear of the camshaft position actuator, proceed with this procedure. If there are four screws (Delphi Actuator) in the rear of the camshaft position actuator, this procedure CANNOT be used. Call GM Technical Assistance for direction.

Use a 1.5 mm and a 2.5 mm hex wrench as a determination gauge to measure the gap between the rear of the camshaft position actuator and the front camshaft cap of both camshafts of the suspect head.

1. Position a screwdriver or medium pry bar between the camshaft cap and camshaft lobe.
2. Apply force to move the camshaft forward. Be cautious not to damage the camshaft lobe while applying this force.



3. With the camshaft moved fully forward, try to insert the 2.5 mm hex wrench between the intake camshaft position actuator and the front camshaft cap. It may be necessary to turn the wrench to align the flat sides of the wrench with the gap between the actuator and the cap.

Important: Prior to replacing a cylinder head assembly, dealers will need to call the PQC at 1-866-654-7654.

4. If the wrench fits between the camshaft position actuator and the front camshaft cap, it will be necessary to replace the cylinder head assembly (refer to the Cylinder Head Replacement procedure in SI) with the appropriate part number listed in this bulletin. WHEN REPLACING THE CYLINDER HEAD, ALSO INSTALL A THRUST WASHER BETWEEN EACH CAMSHAFT POSITION ACTUATOR AND THE FRONT CAMSHAFT CAP.
5. If the wrench does not fit between the camshaft position actuator and the front camshaft cap, continue with the procedure.
6. Position a screwdriver or medium pry bar between the camshaft cap and camshaft lobe.
7. Apply force to move the camshaft rearward. Be cautious not to damage the camshaft lobe while applying this force.
8. With the camshaft moved fully rearward, try to insert the 1.5 mm hex wrench between the camshaft position actuator and the front cam cap. It may be necessary to turn the wrench to align the flat sides of the wrench with the gap between the actuator and the cap.
9. If the 1.5 mm hex wrench does NOT fit between the camshaft position actuator and the front camshaft cap, install the camshaft thrust washers between BOTH camshaft position actuators and the front camshaft cap on the suspect head. Follow the Camshaft Thrust Washer Installation procedure below.

Camshaft Thrust Washer Installation Procedure

Tip
The cylinder head gasket kit contains all the gaskets and seals necessary to perform this repair.

1. Disconnect the engine wiring harness electrical connectors from the intake and exhaust camshaft position (CMP) actuator solenoid valves and sensors.
2. Remove the intake and exhaust CMP sensor bolts and sensors.
3. Remove the intake and exhaust CMP actuator solenoid valve bolts and valves.




Important: Rotate the crankshaft balancer bolt in a clockwise direction ONLY.

4. Rotate the crankshaft balancer using the balancer bolt until the camshafts are in a neutral (low tension) position. The camshafts will be parallel with the camshaft cover rail (1).



5. Use a paint stick to create an alignment mark on one of the timing chain links (2) and the adjacent tooth on the exhaust camshaft position actuator (1).
6. Use a paint stick to create an alignment mark on one of the timing chain links (3) and the adjacent tooth on the intake camshaft position actuator (4).
7. Use an open end wrench on the hex cast into the left intake and exhaust camshafts and rotate the camshafts toward each other in order to create slack in the chain between the actuators.



8. Unscrew the Timing Chain Retention Tool EN-48313 so that the legs of the tool are retracted.
9. Insert the Timing Chain Retention Tool EN-48313 between the camshaft actuators, rearward of the timing chain until the bottom line that is scribed in the body of the tool (2) is adjacent to the top surface of the cylinder head (1). This is the approximate installed position.




Important: The engine front cover is removed for clarity in the following graphics, but NOT required to perform the procedure.

10. Ensure that the feet (4) on the legs of the tool are facing the front of the engine.
11. Partially expand the legs (1, 3) of the Timing Chain Retention Tool EN-48313 by turning the T-shaped handle clockwise.
12. Insert the leg of the tool (1) behind the timing chain guide (2).
13. Continue expanding the Timing Chain Retention Tool EN-48313 until the legs (1, 3) contact the timing chain. Do not tighten at this time.




Important: Ensure that the foot (1) of the Timing Chain Retention Tool EN-48313 is engaged into one of the link pockets to prevent tool slippage during tightening of the Timing Chain Retention Tool EN-48313.

14. Hand tighten the Timing Chain Retention Tool EN-48313.
15. Use an open end wrench on the hex cast into the left intake and exhaust camshafts and rotate the camshafts toward each other in order to create slack in the chain between the actuators.



16. The Timing Chain Retention Tool EN-48313 is now properly installed to hold the timing chain in position.



17. Use an open end wrench on the hex cast into the camshaft in order to prevent engine rotation when loosening the camshaft position actuator bolt.

Note: It is not necessary to completely remove the camshaft actuator from the engine in order to install the thrust washers.

18. Remove the intake camshaft position actuator bolt.



19. Move the camshaft position actuator forward enough to slip the camshaft thrust washer over the front of the intake camshaft and position it against the cylinder head.
20. Position the intake camshaft actuator to the camshaft and install the actuator bolt hand tight.
21. Remove the exhaust camshaft position actuator bolt.
22. Move the camshaft position actuator forward enough to slip the camshaft thrust washer over the front of the exhaust camshaft and position it against the cylinder head.
23. Position the exhaust camshaft actuator to the camshaft and install the actuator bolt hand tight.
24. Remove the Timing Chain Retention Tool EN-48313.



25. Tighten the intake and exhaust camshaft position actuator bolts. Use an open end wrench on the hex cast into the camshaft in order to prevent engine rotation when tightening the camshaft position actuator bolts.

Tighten
Tighten the bolts to 58 N·m (43 lb ft).

26. Install the intake and exhaust camshaft position actuator solenoid valves and bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

27. Install the intake and exhaust camshaft position sensors and bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).

28. Connect the engine wiring harness electrical connectors to the intake and exhaust camshaft position (CMP) sensors and actuator solenoid valves.

To obtain the camshaft thrust washer, fax the form included in this bulletin to the GM Warranty Parts Center (WPC). Request WPC #442.

Important: When ordering the cylinder head gasket for cylinder head replacement, the kit does not include the M11 head bolts or exhaust manifold gaskets, which will need to be ordered separately.

For part numbers and usage of necessary gaskets, refer to Group 00 6-Cylinder Engine of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate Parts & Illustration Catalog for the vehicle.

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

For vehicles repaired under warranty, use:

IMPORTANT NOTE WHEN PRINTING THIS FORM: If the form prints out on two pages, make certain you fax BOTH pages so that the WPC receives all the needed information. Missing information will delay or prevent the part from being shipped.