OTC 6685 - Timing Chain Tensioner Loading Tools (No. 527061-1 & 527061-2); Operation and Specifications

No. 527061-1 & 527061-2
Timing Chain Tensioner
Loading Tools
Applications: 2.0L VIN P 4-cylinder engine used in
2005-2007 Chevrolet Cobalt
2.2L DOHC VIN F 4-cylinder engine used in
2002-2005 Chev Cavalier, 2003-2007 Chev Malibu,
2004-2005 Chev Classic, 2005-2007 Chev Cobalt,
2002-2004 Olds Alero, 2002-2005 Pontiac Sunre
and Grand Am, 2000-2005 Saturn L Series,
2002-2007 Saturn Vue, 2003-2007 Saturn ION
2.4L VIN B 4-cylinder engine used in
2005-2007 Chevrolet Cobalt and HHR,
2005-2007 Pontiac G6, Solstice, and Pursuit
NOTE: No. 527061-1 and No. 527061-2 timing chain
tensioner loading tools must be used together.
1. Remove the piston assembly from the body of the timing
chain tensioner by pulling it out. See Figure 1.
2. Install the No. 527061-2 into a vise. See Figure 2.
3. Install the piston assembly into No. 527061-2. See Figure
2.
4. Using No. 527061-1, turn the rachet cylinder into the
piston assembly. See Figure 2.
No. 527061-1
No. 527061-2
Figure 1
Piston
Assembly
Remove
Tensioner
Body
Figure 3
72 mm
(2.83 in.)
Tensioner
Body
Piston
Assembly
Install
527061-2
527061-1
Ratchet
Cylinder
Piston
Assembly
Turn
Figure 2
5. Install the compressed piston assembly back into the timing
chain tensioner body until it stops at the bottom of the bore.
See Figure 3. Note: Do not compress the piston assembly
against the bottom of the bore. This will activate the
tensioner, which will then need to be reset.
6. Measure the tension from end to end. It should measure
approximately 72 mm (2.83 inches). If it measures more
than this, the rachet cylinder in the piston assembly is not
fully compressed. Steps 2, 3, & 4 must be repeated until the
tension measures correctly.
CAUTION: To prevent personal injury, wear eye
protection that meets ANSI Z87.1 and OSHA standards.
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