Engine Cranks with No Start or Engine has Extended Crank (Greater than 3 Seconds) Before Starting (Verify Timing of Camshaft Position Trigger and Adjust, If Necessary)

Some customers may comment on a no start or an extended crank (greater than 3 seconds) before start condition.

The camshaft position trigger may not be properly timed to the camshaft.

Verify the timing of the camshaft position trigger and adjust if necessary.

1. Disconnect the negative battery cable.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.

2. Raise vehicle on hoist until the tires are off the ground.
3. Remove right front tire.
4. Remove inner right side splash shield to gain access to crankshaft pulley.
5. Remove cylinder #4 ignition coil and spark plug.

Important: To determine #4 cylinder TDC compression stroke, rotate the engine by the crankshaft pulley. A puff of air will be felt as the piston travels upward on the compression stroke. Once a puff of air is felt, continue to rotate the crankshaft pulley until the timing mark is aligned as shown in illustration.




6. Rotate the engine to bring the cylinder #4 to top dead center (TDC) compression stroke. The crankshaft pulley-timing notch should be aligned with the timing mark on the front cover.
7. Remove Engine Control Module (ECM) from mounting bracket.
8. Remove the Under Hood Electrical Center. (Refer to the Under Hood Electrical Center or Junction Block Bracket Replacement in the 2004 ION Wiring Systems section of the Body Section of SI - Document ID #1199660).
9. Remove the two fasteners holding the clutch master cylinder to the front of dash to allow easier access to the camshaft position sensor housing.
10. Remove the brake booster vacuum hose from the supercharger and set it aside.
11. Remove the two fasteners holding the camshaft position sensor housing assembly to the cylinder head.
12. Slide the camshaft position sensor housing assembly back away from the cylinder head.
13. Remove and discard camshaft position sensor housing seal.
14. Using a shop towel, wipe clean the "Cog" of the camshaft position trigger and the mating surfaces of the camshaft position sensor housing assembly and the cylinder head.
15. Install a new camshaft position sensor housing seal.





16. Align the timing mark on the "Cog" to the timing mark on the camshaft position sensor housing assembly.

Important: Make sure the "Cog" does not rotate before it seats inside the camshaft.

17. Install the camshaft position sensor housing assembly to the cylinder head.
18. Install the two fasteners for the camshaft position sensor housing assembly.

Tighten
Tighten the fasteners to 22N·m(16 ft-lbs).

19. Install brake booster vacuum hose to supercharger.
20. Install the two fasteners to the clutch master cylinder.

Tighten
Tighten the fasteners to 10N·m (89 in-lbs).

21. Install the Under Hood Electrical Center. (Refer to the Underhood Electrical Center or Junction Block Bracket Replacement in the 2004 ION Wiring Systems section of the Body Section of SI - Document ID #1199660).
22. Install ECM.
23. Install the right front inner splash shield.
24. Install the right front tire.

Tighten
Tighten the wheel nuts to 140N·m(100 ft-lbs).

25. Lower vehicle.
26. Install negative battery cable.

Tighten
Tightenthe battery cable to 17N·m(14 ft-lbs).

27. Verify condition has been repaired.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J0819 (Housing Assembly and/or Seal, Camshaft Position Sensor - R & R or Replace).