AutoZone 1989 Mercury Colony Park 5.0L FI 8cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Timing Chain & Sprockets 1 | AutoZone.com

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    1989 Mercury Colony Park 5.0L FI 8cyl

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    Lexus GS, SC 1998-06

    Timing Chain & Sprockets 1

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    Removal & Installation



    1uz-FE Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Relieve the fuel pressure from the fuel lines.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable. Wait at least 90 seconds before performing any other work
       
      Positive battery cable
       
      Battery
       
      Air cleaner inlet
       
      V bank cover by removing the bolt and 2 cap nuts
       
      Air cleaner and intake air connector assembly
       
      Drive belt
       
      Fluid coupling and the fan pulley. The drive belt tension may be slackened by turning the tensioner counterclockwise. The pulley bolt for the drive belt tensioner has a left-handed thread.
       
      Radiator
       
      The right-hand No. 3 timing belt cover
       
      Left-hand No. 3 timing belt cover
       
      Evaporative Emissions (EVAP) hose clamp from the timing belt cover. For all other vehicles, disconnect the EVAP hose from the hose clamp on the timing belt cover.
       
      4 bolts to the left-hand timing belt cover
       
      Cord grommet from the timing belt cover and remove the timing belt cover
       
      Drive belt idler pulley by removing the pulley bolt and cover plate
       
      Right-hand and left No. 2 timing belt covers
       
      No. 1 ignition coil
       
      Air conditioning compressor from the engine. Do NOT disconnect the air conditioning pressure lines.
       
      Fan bracket by removing the 2 bolts and 2 nuts
       
      Alternator from the engine
       
      Drive belt tensioner
       

    6.  
    7. Set the engine to Top Dead Center (TDC) on cylinder No. 1.
    8.  
    9. Turn the crankshaft pulley approximately 50°clockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.
      WARNING
      If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley. Always set the crankshaft pulley at the correct angle before removing the timing belt.

    10.  
    11. If the timing belt is to be reused, turn the crank pulley slowly; check that the 3 installation marks are present on the belt. If the marks are not present, make new installation marks before removing the belt. The marks should align with the timing marks on each camshaft pulley and the crank pulley.
    12.  
    13. Remove or disconnect the following:
      WARNING
      Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.



      Timing belt tensioner
       
      Timing belt from the camshaft timing pulleys
       
      Camshaft timing pulleys
       
      No. 2 ignition coil
       
      Rear timing belt plates
       
      Throttle body
       
      Spark plug wires, wire clamps and the wire cover assembly from the right cylinder head
       
      Right cylinder head cover by removing the 8 bolts and 8 washers
       
      Transmission oil dipstick
       
      Evaporative Emission (EVAP) control hose from the Vacuum Switching Valve (VSV)
       
      Engine wire clamp from the wire bracket on the delivery pipe
       
      Spark plug wires and clamps from the left-hand cylinder head cover
       
      Left cylinder head cover by removing the 8 bolts and 8 seal washers
       
      Semi-circular plugs, if necessary
       

    14.  
    15. To remove the exhaust camshaft from the right side cylinder head:
      1. Position the service bolt hole of the drive subgear to the upright position. Secure the camshaft subgear to drive gear with a service bolt.
      2.  
      3. Set the timing mark (single dot) on the camshaft drive gear at approximately 10°. Turn the camshaft with a wrench on the hexagonal flats.
      4.  
      5. Alternately loosen and remove the bearing cap bolts holding the intake camshaft side of the oil feed pipe to the cylinder head.
      6.  
      7. Uniformly loosen (in several passes) and remove the bearing cap bolts, in sequence.
      8.  
      9. Remove the oil feed pipe and the bearing caps. Remove the camshaft.
      10.  
      11. To remove the intake camshaft from the right side cylinder head:
      12.  
      13. Set the timing mark (single dot) on the camshaft drive gear at approximately 45°. Turn the camshaft with a wrench on the hexagonal flats.
      14.  
      15. Uniformly loosen (in several passes) and remove the bearing cap bolts in the proper sequence.
      16.  
      17. Remove the bearing caps, oil seal and the intake camshaft.
      18.  

    16.  
    17. To remove the exhaust camshaft of the left side cylinder head:
      1. Position the service bolt hole of the drive subgear to the upright position. Secure the camshaft subgear to drive gear with a service bolt.
        NOTE
        When removing the camshaft, be sure the torsional spring force of the subgear has been eliminated.

      2.  
      3. Set the timing mark (2 dots) on the camshaft drive gear at approximately 15°, by turning the camshaft with the proper tool.
      4.  
      5. Alternately loosen and remove the bearing cap bolts holding the intake camshaft side of the oil feed pipe to the cylinder head.
      6.  
      7. Uniformly loosen (in several passes) and remove the bearing cap bolts in the proper sequence.
      8.  
      9. Remove the oil feed pipe and the bearing caps. Remove the camshaft.
      10.  

    18.  
    19. To remove the intake camshaft from the left side cylinder head:
      1. Set the timing mark (single dot) of the camshaft drive gear at approximately 60°, by turning the camshaft with the proper tool.
      2.  
      3. Uniformly loosen (in several passes) and remove the bearing cap bolts, in sequence.
      4.  
      5. Remove the bearing caps, oil seal and the intake camshaft.
      6.  
      7. Remove the valve lash adjuster shims and hydraulic lash adjusters. Identify each lash adjuster and shim as it is removed so it can be reinstalled in the same position. If the lash adjusters are to be reused, store them upside down in a sealed container.

        Click image to see an enlarged view

        Fig. Bolt loosening sequence for the intake and exhaust camshaft bearing caps on the right cylinder head-4.0L (1UZ-FE) engine



        Click image to see an enlarged view

        Fig. Set the timing mark (2 dots) on the camshaft drive gear, by turning the camshaft with the proper tool.-4.0L (1UZ-FE) engine



        Click image to see an enlarged view

        Fig. Bolt loosening sequence for the intake and exhaust camshaft bearing caps on the left cylinder head-4.0L (1UZ-FE) engine

      8.  

    20.  

    To install:

    1. Install or connect the following:

      Valve lash adjusters and shims. Check the valve clearance and replace the shims as necessary.
       
      New seal packing to the bearing caps
       
      Bearing cap on the right side cylinder head, marked I1 , in position with the arrow mark facing the rear. Install the bearing cap on the left side cylinder head, marked I6 , in position with the arrow mark facing the front.
       
      Oil on the threads of the cap bolts. Install the bearing cap bolts with new washers and tighten to 12 ft. lbs. (16 Nm).
       

    2.  
    3. To install the right side cylinder head intake camshaft:
      1. Apply grease to the thrust portion of the camshaft.
      2.  
      3. Place the intake camshaft at a 45° angle of the timing mark (single dot) on the cylinder head.
      4.  
      5. Remove any old packing and apply new seal packing to the bearing cap marked I6 and install the front bearing cap, marked I6 with the arrow facing rearward.
      6.  
      7. Align the arrows at the front and rear of the cylinder head with the bearing cap.
      8.  
      9. Install the remaining bearing caps in the proper sequence with the arrow mark facing rearward. Install the oil feed pipe and the mounting bolts.
      10.  
      11. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm).

        Click image to see an enlarged view

        Fig. Installing the camshaft bearing caps in sequence on the camshaft (right shown)-4.0L (1UZ-FE) engine



        Click image to see an enlarged view

        Fig. Bolt tightening sequence for the intake and exhaust camshaft bearing caps on the right cylinder head-4.0L (1UZ-FE) engine



        Click image to see an enlarged view

        Fig. Bolt tightening sequence for the intake and exhaust camshaft bearing caps on the left cylinder head-4.0L (1UZ-FE) engine

      12.  

    4.  
    5. To install the right side cylinder head exhaust camshaft:
      1. Set the timing mark (single dot) on the camshaft drive gear at a 10° angle by turning the intake camshaft with the proper tool.
      2.  
      3. Apply grease to the thrust portion of the camshaft.
      4.  
      5. Align the timing marks (single dots) on the camshaft drive and driven gears.
      6.  
      7. Place the exhaust camshaft in the cylinder head. Install the rear bearing cap with the arrow mark facing rearward.
      8.  
      9. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Apply a light coat of oil on the threads of the bearing cap bolts.
      10.  
      11. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm).
      12.  
      13. Bring the service bolt installed upward by turning the camshaft with the proper tool. Remove the service bolt.
      14.  

    6.  
    7. To install the left side cylinder head intake camshaft:
      1. Apply grease to the thrust portion of the camshaft.
      2.  
      3. Place the intake camshaft with the timing mark (single dot) at a 60° angle on the cylinder head.
      4.  
      5. Remove any old packing and apply new seal packing to the bearing cap marked I6 and install the front bearing cap, marked I1 with the arrow facing rearward.
      6.  
      7. Align the arrows at the front and rear of the cylinder head with the bearing cap. Apply a light coat of oil on the threads of the bearing cap bolts.
      8.  
      9. Install the remaining bearing caps in the proper sequence with the arrow mark facing rearward. Install the oil feed pipe and the mounting bolts.
      10.  
      11. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm).
      12.  

    8.  
    9. Install the left side cylinder head exhaust camshaft by:
      1. Set the timing mark (2 dots) on the camshaft drive gear at a 15 degree angle by turning the intake camshaft with the proper tool.
      2.  
      3. Apply grease to the thrust portion of the camshaft.
      4.  
      5. Align the timing marks (2 dots each) on the camshaft drive and driven gears.
      6.  
      7. Place the exhaust camshaft on the cylinder head. Install the rear bearing cap with the arrow mark facing rearward.
      8.  
      9. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Apply a light coat of oil on the threads of the bearing cap bolts.
      10.  
      11. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm).
      12.  

    10.  
    11. Bring the service bolt installed upward by turning the camshaft with the proper tool. Remove the service bolt.
    12.  
    13. Install or connect the following:

      Camshaft oil seals. Be sure to apply Multi-Purpose (MP) grease to the new oil seal lip.
       
      Semi-circular plugs to the cylinder heads
       
      Left cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
       
      Spark plug wires and clamps to the left cylinder head cover
       
      Engine wire clamp to the wire bracket on the delivery pipe
       
      EVAP hose to the VSV
       
      Transmission oil dipstick
       
      Right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
       
      Spark plug wires and clamps to the right cylinder head cover
       
      Throttle body to the air intake chamber. Install the 2 bolts and 2 nuts and tighten to 13 ft. lbs. (18 Nm).
       
      Timing belt rear plates by installing the bolts. Tighten the bolts to 66 inch lbs. (8 Nm).
       
      No. 2 ignition coil
       

    14.  
    15. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
    16.  
    17. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).
    18.  
    19. Turn the crankshaft pulley and align its groove with the 0 timing mark on the timing belt cover.
    20.  
    21. Turn each camshaft timing pulley and align the timing marks of the pulley with the timing belt rear plate.
    22.  
    23. Attach the timing belt to the left side camshaft timing pulley:
    24.  
    25. Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left side camshaft pulley.
    26.  
    27. Align the timing marks of the left side camshaft pulley and the timing belt rear plate.
    28.  
    29. Check that the timing belt has tension between crankshaft timing pulley and the left side camshaft pulley.
    30.  
    31. Install the timing belt to the right side camshaft timing pulley:
    32.  
    33. Using the proper tool, slightly turn the right side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the right side camshaft pulley.
    34.  
    35. Align the timing marks of the right side camshaft pulley and the timing belt rear plate.
    36.  
    37. Check that the timing belt has tension between crankshaft timing pulley and the right side camshaft pulley.
    38.  
    39. The timing belt tensioner must be set prior to installation. The tensioner can be set by:
      1. Place a plate washer between the tensioner and a block. Using a press, press in the pushrod using 220-225 lbs. (100-102 kg.) of pressure.
      2.  
      3. Align the holes of the pushrod and housing, pass a 0.05 in. (1.27mm) rod through the holes to keep the setting position of the pushrod.
      4.  
      5. Release the press and install the dust boot to the tensioner.
      6.  
      7. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner.
      8.  
      9. Turn the crankshaft pulley 2 complete revolutions from TDC to TDC. Always turn the crankshaft clockwise. Check that all belt and pulley marks align with their reference marks. If any mark is out of perfect alignment, the timing belt must be removed and reinstalled.
      10.  

    40.  
    41. Install or connect the following:

      Remaining components
       
      V-bank cover
       
      Coolant
       
      Battery and battery tray
       
      Battery cables, positive cable first
       
      Air cleaner inlet
       
      Battery clamp cover
       
      Engine undercover
       
      Oil pan protector
       

    42.  

    2jz-Ge Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable from the battery
       
      Timing belt from the engine
       
      Cylinder head covers
       

    4.  
    5. Make reference marks on the timing belt to the crankshaft and idler pulley timing marks.
    6.  
    7. Remove the timing belt. See TIMING BELT.
      WARNING
      Do NOT allow anything to drop into the lower part of the timing belt cover. Do NOT allow the timing belt to come in contact with any oil, water or dust.

    8.  
    9. Remove both the exhaust and intake camshaft pulleys. See procedure under TIMING BELT.
      WARNING
      Since the thrust clearance of the camshaft is small, the camshaft must be kept level during removal. If not, the portion of the cylinder head receiving the camshaft thrust may crack or be otherwise damaged, causing the camshaft to later seize or break. Follow the camshaft removal procedure carefully as given in this section.

    10.  
    11. With a 5mm hex wrench, remove the No. 3 camshaft bearing cap bolts. Then, uniformly loosen and remove the 4 camshaft bearing cap bolts, located just rear of the camshaft pulley locations.
    12.  
    13. Carefully pry out the No. 1 and No. 3 camshaft bearing caps and oil seals.
    14.  
    15. Uniformly loosen and remove the 12 camshaft bearing cap bolts, in several passes, and following the sequence illustrated. Remove the 6 No. 2 bearing caps and the camshafts from the engine.

      Click image to see an enlarged view

      Fig. Camshaft bearing cap bolt removal sequence-3.0L (2JZ-GE) engine

    16.  

    To install:

    1. Apply engine oil to the thrust portion of the camshaft.
    2.  
    3. Place the camshaft into the cylinder head, with the cam lobe facing up (cam lobe mark on the exhaust camshaft will be at about 11 o-clock and the cam lobe mark on the intake camshaft will be at 3 o-clock).
    4.  
    5. Place the No. 3 and No. 7 camshaft journal bearing caps into their positions. Apply engine oil onto thread and under the heads of the bearing cap bolts. Temporarily tighten these bearing cap bolts, uniformly and alternately, until they are snug with the cylinder head.
    6.  
    7. Apply grease to new camshaft oil seal lip. Install both oil seals onto the camshafts.
    8.  
    9. Clean the installed surface of the No. 1 and No. 3 camshaft bearing caps and cylinder head. Apply seal packing along outer edge of bearing cap, outside of the bolt hole.

      Click image to see an enlarged view

      Fig. Installing packing onto camshaft bearing caps-3.0L (2JZ-GE) Engine

    10.  
    11. Install the other bearing caps in proper locations. Apply a light coat of engine oil to bolt threads and under the bolt heads. Install and uniformly tighten the 14 bearing cap bolts on one side, in several passes, following sequence shown. Torque these bolts to 15 ft. lbs. (20 Nm).

      Click image to see an enlarged view

      Fig. Camshaft bearing cap bolt tightening sequence-3.0L (2JZ-GE) engine

    12.  
    13. Using a 5mm hex wrench, tighten bearing cap bolts for caps No. 2 and No. 3 to 44 inch lbs. (5 Nm).
    14.  
    15. With a special oil seal driver, install the 2 oil seals as far as possible by pushing from front end of camshafts.
    16.  
    17. Rotate camshaft with a wrench on the hex section and bring the forward straight pin up to the 12 o-clock position. Loosen the 12 bearing cap bolts, highlighted in the Step 1 figure, until bolts are just finger-tight. Now, retighten these bolts, in several passes, to 15 ft. lbs. (20 Nm).

      Click image to see an enlarged view

      Fig. Tightening the camshafts (Step 1)-3.0L (2JZ-GE) engine

    18.  
    19. Turn camshaft 1/3 of a revolution clockwise, so straight pin is at about the 4 o-clock position. Now, loosen the 8 bolts, as highlighted in Step 2 illustration, until they are just finger-tight. Now, retighten these bolts, in several passes, to 15 ft. lbs. (20 Nm).

      Click image to see an enlarged view

      Fig. Tightening the camshafts (Step 2)-3.0L (2JZ-GE) engine

    20.  
    21. Turn the camshaft an additional 1/3 of a revolution, so the straight pin in now at about the 8 o-clock position. Loosen the 8 bearing cap bolts, as highlighted in Step 3 illustration, until they are just finger-tight. Now, retighten these bolts, in several passes, to 15 ft. lbs. (20 Nm).

      Click image to see an enlarged view

      Fig. Tightening the camshafts (Step 3)-3.0L (2JZ-GE) engine

    22.  
    23. Check and adjust the valve lash. See VALVE LASH
    24.  
    25. Install the No. 4 timing belt cover.
    26.  
    27. Align the exhaust camshaft knock pin with the groove in the camshaft pulley and slide on the pulley. Ensure the front mark is forward. Hold the hex portion of the exhaust camshaft and tighten the exhaust pulley center bolt to 60 ft. lbs. (81 Nm).
    28.  
    29. Align the intake camshaft knock pin with the groove in the camshaft pulley and slide the pulley into place until it touches bottom. Check that outer circumference of the intake pulley rotates easily through 30°.
    30.  
    31. Holding the hex portion of the intake camshaft, install and tighten the intake camshaft pulley bolt to 60 ft. lbs. (81 Nm). Using a 14mm hex wrench, install the straight screw plug, with a seal washer to the set bolt. Torque it to 11 ft. lbs. (15 Nm).
    32.  
    33. Align the dot mark on the intake camshaft pulley with the timing mark of the No. 4 timing belt cover.
    34.  
    35. Reinstall the timing belt, making sure its position on the crankshaft pulley does not change, and that the marks made on the timing belt line up with the camshaft pulley timing marks.
    36.  
    37. Clean any old packing material from outside of the 2 rearmost bearing caps and install new packing in its place.
    38.  
    39. Reinstall remaining components in reverse of the removal procedure.
    40.  

     
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