Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Camshaft, Bearings & Lifters 3

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Removal & Installation



6.5L Engine
  1. Drain the cooling system.
  2.  
  3. Discharge the air conditioning system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Battery cables
     
    Radiator, condenser, shroud and fan assembly
     
    Grille and parking light assembly
     
    Hood latch and brace assembly
     
    Oil pump drive
     
    Power steering pump and position aside
     
    Alternator
     
    Air conditioner compressor and position aside
     
    Rocker arm covers
     
    Rocker arm assemblies and pushrods. Mark them so they can be returned to their original position.
     
    Cylinder heads
     
    Hydraulic lifters; keep them in order so they can be returned to their original bore
     
    Front cover
     
    Timing chain and camshaft sprocket
     
    Injector pump
     
    Front engine mounting through-bolts
     
    Air conditioner condenser mounting bolts and lift the condenser out
     
    Thrust plate bolts and thrust plate
     
    Camshaft from the block
     
    Thrust plate spacer, if necessary
     

  8.  

To install:

  1. Install the spacer with the I.D. chamfer toward the camshaft.
    NOTE
    It is recommended that the engine oil, oil filter and hydraulic lifters be replaced when installing a new camshaft.

  2.  
  3. Coat the camshaft lobes with Molykote® or equivalent.
  4.  
  5. Lubricate the camshaft journals with engine oil.
  6.  
  7. Install or connect the following:

    Camshaft carefully into the block
     
    Thrust plate and bolts. Tighten to 17 ft. lbs. (23 Nm).
     
    Engine mount through-bolts
     
    Timing chain and sprockets, align the timing marks
     
    Air conditioner condenser, if equipped
     
    Injector pump
     
    Front cover
     
    Cylinder head
     
    Hydraulic lifters in the same bore as they were removed
     
    Rocker arm assemblies and pushrods in their original locations
     
    Rocker arm covers
     
    Power steering pump, alternator and air conditioner compressor
     
    Oil pump drive
     
    Hood latch and brace
     
    Grille and parking light assembly
     
    Radiator, the shroud and fan assembly
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.

    Click image to see an enlarged view

    Fig. Exploded view of the lifter, guide plate and clamp-6.5L diesel engines

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge the air conditioning system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Battery cables
     
    Radiator, condenser, shroud and fan assembly
     
    Grille and parking light assembly
     
    Hood latch and brace assembly
     
    Oil pump drive
     
    Power steering pump and position aside
     
    Alternator, air conditioner compressor and position aside
     
    Rocker arm covers
     
    Rocker arm assemblies and pushrods. Mark them so they can be returned to their original position.
     
    Cylinder heads
     
    Hydraulic lifters and keep them in order so they can be returned to their original bore
     
    Front cover
     
    Timing chain and camshaft sprocket
     
    Injector pump
     
    Front engine mounting through-bolts
     
    Air conditioner condenser mounting bolts and lift the condenser out
     
    Thrust plate bolts and thrust plate
     
    Camshaft from the block
     
    Thrust plate spacer, if necessary
     

  10.  

To install:

  1. Install the spacer with the ID chamfer toward the camshaft.
    NOTE
    It is recommended that the engine oil, oil filter and hydraulic lifters be replaced when installing a new camshaft.

  2.  
  3. Coat the camshaft lobes with Molykote® or equivalent.
  4.  
  5. Lubricate the camshaft journals with engine oil.
  6.  
  7. Install or connect the following:

    Camshaft carefully into the block
     
    Thrust plate and bolts. Tighten to 17 ft. lbs. (23 Nm).
     
    Engine mount through-bolts
     
    Timing chain and sprockets, align the timing marks
     
    Air conditioner condenser, if equipped
     
    Injector pump
     
    Front cover
     
    Cylinder head
     
    Hydraulic lifters in the same bore as they were removed
     
    Rocker arm assemblies and pushrods in their original locations
     
    Rocker arm covers
     
    Power steering pump, alternator and air conditioner compressor
     
    Oil pump drive
     
    Hood latch and brace
     
    Grille and parking light assembly
     
    Radiator, the shroud and fan assembly
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.

    Click image to see an enlarged view

    Fig. Exploded view of the lifter, guide plate and clamp-6.5L diesel engines

  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge the air conditioning system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Battery cables
     
    Radiator, condenser, shroud and fan assembly
     
    Grille and parking light assembly
     
    Hood latch and brace assembly
     
    Oil pump drive
     
    Power steering pump and position aside
     
    Alternator, air conditioner compressor and position aside
     
    Rocker arm covers
     
    Rocker arm assemblies and pushrods. Mark them so they can be returned to their original position.
     
    Cylinder heads
     
    Hydraulic lifters and keep them in order so they can be returned to their original bore
     
    Front cover
     
    Timing chain and camshaft sprocket
     
    Injector pump
     
    Front engine mounting through-bolts
     
    Air conditioner condenser mounting bolts and lift the condenser out
     
    Thrust plate bolts and thrust plate
     
    Camshaft from the block
     
    Thrust plate spacer, if necessary
     

  10.  

To install:

  1. Install the spacer with the ID chamfer toward the camshaft.
    NOTE
    It is recommended that the engine oil, oil filter and hydraulic lifters be replaced when installing a new camshaft.

  2.  
  3. Coat the camshaft lobes with Molykote® or equivalent.
  4.  
  5. Lubricate the camshaft journals with engine oil.
  6.  
  7. Install or connect the following:

    Camshaft carefully into the block
     
    Thrust plate and bolts. Tighten to 17 ft. lbs. (23 Nm)
     
    Engine mount through-bolts
     
    Timing chain and sprockets, Align the timing marks
     
    Air conditioner condenser, if equipped
     
    Injector pump
     
    Front cover
     
    Cylinder head
     
    Hydraulic lifters in the same bore as they were removed
     
    Rocker arm assemblies and pushrods in their original locations
     
    Rocker arm covers
     
    Power steering pump, alternator and air conditioner compressor
     
    Oil pump drive
     
    Hood latch and brace
     
    Grille and parking light assembly
     
    Radiator, the shroud and fan assembly
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.

    Click image to see an enlarged view

    Fig. Exploded view of the lifter, guide plate and clamp-6.5L diesel engines

  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge the air conditioning system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Battery cables
     
    Radiator, condenser, shroud and fan assembly
     
    Grille and parking light assembly
     
    Hood latch and brace assembly
     
    Oil pump drive
     
    Power steering pump and position aside
     
    Alternator, air conditioner compressor and position aside
     
    Rocker arm covers
     
    Rocker arm assemblies and pushrods. Mark them so they can be returned to their original position.
     
    Cylinder heads
     
    Hydraulic lifters and keep them in order so they can be returned to their original bore
     
    Front cover
     
    Timing chain and camshaft sprocket
     
    Injector pump
     
    Front engine mounting through-bolts
     
    Air conditioner condenser mounting bolts and lift the condenser out
     
    Thrust plate bolts and thrust plate
     
    Camshaft from the block
     
    Thrust plate spacer, if necessary
     

  10.  

To install:

  1. Install the spacer with the ID chamfer toward the camshaft.
    NOTE
    It is recommended that the engine oil, oil filter and hydraulic lifters be replaced when installing a new camshaft.

  2.  
  3. Coat the camshaft lobes with Molykote® or equivalent.
  4.  
  5. Lubricate the camshaft journals with engine oil.
  6.  
  7. Install or connect the following:

    Camshaft carefully into the block
     
    Thrust plate and bolts. Tighten to 17 ft. lbs. (23 Nm)
     
    Engine mount through-bolts
     
    Timing chain and sprockets, Align the timing marks
     
    Air conditioner condenser, if equipped
     
    Injector pump
     
    Front cover
     
    Cylinder head
     
    Hydraulic lifters in the same bore as they were removed
     
    Rocker arm assemblies and pushrods in their original locations
     
    Rocker arm covers
     
    Power steering pump, alternator and air conditioner compressor
     
    Oil pump drive
     
    Hood latch and brace
     
    Grille and parking light assembly
     
    Radiator, the shroud and fan assembly
     
    Negative battery cables
     

  8.  
  9. Refill the cooling system with the proper type and quantity of antifreeze.

    Click image to see an enlarged view

    Fig. Exploded view of the lifter, guide plate and clamp-6.5L diesel engines

  10.  

6.6L Engine

NOTE
This procedure requires the use of the following special tools: Flywheel Holding Tool No. J 44643, Magnetic Base J 26900-13 and Dial Indicator J 26900-12.

  1. Properly discharge the A/C system.
  2.  
  3. Remove or disconnect the following:

    Both cylinder heads
     
    Valve lifter guide hold-down bracket bolts
     
    Valve lifter guide hold-down brackets
     
    Valve lifter guides
     
    Valve lifters
     
    Charged air cooler
     
    A/C condenser
     
    Starter
     

  4.  
  5. Install the Flywheel Holding Tool No. J 44643 in the starter opening. Make sure the tool is flush to the flywheel opening. The holding tool will be used to remove the crankshaft balancer bolt and camshaft drive gear bolt.
    NOTE
    The crankshaft reluctor and oil pump drive gear are timed together at the factory. Do NOT remove the reluctor from the oil pump drive gear.



    Click image to see an enlarged view

    Fig. Proper installation of the flywheel holding tool in the starter opening



    Engine front cover
     
    Oil pump driven gear nut and gear
     



    Oil pump drive gear and crankshaft reluctor assembly. Do not remove the reluctor bolts or damage the reluctor teeth
     

  6.  
  7. Using the Magnetic Base J 26900-13 and Dial Indicator J 26900-12, measure the camshaft end-play. The production value is 0.002-0.0045 in. (0.050-0.114mm) and the service limit is 0.008 in. (0.20mm). Replace the cam gear or thrust plate if the measured value exceeds the service limit.
    NOTE
    Use the flywheel holding tool to hold the engine from turning while loosening the camshaft gear bolt.



    Click image to see an enlarged view

    Fig. Use the dial indicator (1) and magnetic base (2) to measure the camshaft end-play



    Camshaft reluctor screws and reluctor
     



    Loosen the camshaft gear bolt and leave the bolt finger-tight
     
    Camshaft thrust plate bolts through the holes in the camshaft gear
     
    Camshaft with the gear attached
     
    Cam gear bolt and gear
     
    Thrust plate
     

  8.  
  9. Clean and inspect the camshaft and bearings.
  10.  

To install:

  1. Install or connect the following:

    Camshaft thrust plate
     
    Camshaft driven gear
     
    New driven gear bolt (finger-tight)
     
    Camshaft and gear assembly into the cylinder block. Align the gear to the crankshaft gear

    Click image to see an enlarged view

    Fig. Camshaft and crankshaft gear alignment-6.5L engine

     



    Threadlock to the thrust plate bolts
     
    Thrust plate bolts and tighten to 19 ft. lbs. (26 Nm)
     
    Camshaft reluctor to the cam gear
     
    Reluctor bolts. Tighten to 80 inch lbs. (9 Nm) in a crisscross pattern.
     
    If removed, reinstall the flywheel holding tool in the starter opening
     
    Camshaft gear bolt and tighten to 173 ft. lbs. (234 Nm)
     

  2.  
  3. Using the Magnetic Base J 26900-13 and Dial Indicator J 26900-12, measure the camshaft end-play. The production value is 0.002-0.0045 in. (0.050-0.114mm) and the service limit is 0.008 in. (0.20mm). Replace the cam gear or thrust plate if the measured value exceeds the service limit.

    Oil pump drive gear and reluctor to the crankshaft. Do not damage the teeth of the reluctor.
     
    Oil pump driven gear and nut. Tighten to 74 ft. lbs. (100 Nm).
     
    Engine front cover
     
    A/C condenser
     
    Charged air cooler
     

  4.  
  5. Apply clean engine oil to the roller and outside of the lifters.

    Valve lifters
     
    Valve lifter guides
     
    Valve lifter guide hold-down brackets. Make sure that both tabs of the bracket are in the holes of the valve lifter guides.
     
    Valve lifter guide hold-down bracket bolts. Tighten to 97 inch lbs. (11 Nm).
     

  6.  


NOTE
This procedure requires the use of the following special tools: Flywheel Holding Tool No. J 44643, Magnetic Base J 26900-13 and Dial Indicator J 26900-12.

  1. Properly discharge the A/C system.
  2.  
  3. Remove or disconnect the following:

    Both cylinder heads
     
    Valve lifter guide hold-down bracket bolts
     
    Valve lifter guide hold-down brackets
     
    Valve lifter guides
     
    Valve lifters
     
    Charged air cooler
     
    A/C condenser
     
    Starter
     

  4.  
  5. Install the Flywheel Holding Tool No. J 44643 in the starter opening. Make sure the tool is flush to the flywheel opening. The holding tool will be used to remove the crankshaft balancer bolt and camshaft drive gear bolt.
    NOTE
    The crankshaft reluctor and oil pump drive gear are timed together at the factory. Do NOT remove the reluctor from the oil pump drive gear.



    Click image to see an enlarged view

    Fig. Proper installation of the flywheel holding tool in the starter opening-6.6L engines



    Engine front cover
     
    Oil pump driven gear nut and gear
     



    Oil pump drive gear and crankshaft reluctor assembly. Do not remove the reluctor bolts or damage the reluctor teeth
     

  6.  
  7. Using the Magnetic Base J 26900-13 and Dial Indicator J 26900-12, measure the camshaft end-play. The production value is 0.002-0.0045 in. (0.050-0.114mm) and the service limit is 0.008 in. (0.20mm). Replace the cam gear or thrust plate if the measured value exceeds the service limit.
    NOTE
    Use the flywheel holding tool to hold the engine from turning while loosening the camshaft gear bolt.



    Click image to see an enlarged view

    Fig. Use the dial indicator (1) and magnetic base (2) to measure the camshaft end-play-6.6L engines



    Camshaft reluctor screws and reluctor
     



    Loosen the camshaft gear bolt and leave the bolt finger-tight
     
    Camshaft thrust plate bolts through the holes in the camshaft gear
     
    Camshaft with the gear attached
     
    Cam gear bolt and gear
     
    Thrust plate
     

  8.  
  9. Clean and inspect the camshaft and bearings.
  10.  

To install:

  1. Install or connect the following:

    Camshaft thrust plate
     
    Camshaft driven gear
     
    New driven gear bolt (finger-tight)
     
    Camshaft and gear assembly into the cylinder block. Align the gear to the crankshaft gear

    Click image to see an enlarged view

    Fig. Camshaft and crankshaft gear alignment-6.6L engines

     



    Threadlock to the thrust plate bolts
     
    Thrust plate bolts and tighten to 19 ft. lbs. (26 Nm)
     
    Camshaft reluctor to the cam gear
     
    Reluctor bolts. Tighten to 80 inch lbs. (9 Nm) in a crisscross pattern.
     
    If removed, reinstall the flywheel holding tool in the starter opening
     
    Camshaft gear bolt and tighten to 173 ft. lbs. (234 Nm)
     

  2.  
  3. Using the Magnetic Base J 26900-13 and Dial Indicator J 26900-12, measure the camshaft end-play. Replace the cam gear or thrust plate if the measured value exceeds the service limit; refer to the Camshaft Specifications chart.

    Oil pump drive gear and reluctor to the crankshaft. Do not damage the teeth of the reluctor.
     
    Oil pump driven gear and nut. Tighten to 74 ft. lbs. (100 Nm).
     
    Engine front cover
     
    A/C condenser
     
    Charged air cooler
     

  4.  
  5. Apply clean engine oil to the roller and outside of the lifters.

    Valve lifters
     
    Valve lifter guides
     
    Valve lifter guide hold-down brackets. Make sure that both tabs of the bracket are in the holes of the valve lifter guides.
     
    Valve lifter guide hold-down bracket bolts. Tighten to 97 inch lbs. (11 Nm).
     

  6.  


NOTE
This procedure requires the use of the following special tools: Flywheel Holding Tool No. J 44643, Magnetic Base J 26900-13 and Dial Indicator J 26900-12.

  1. Properly discharge the A/C system.
  2.  
  3. Remove or disconnect the following:

    Both cylinder heads
     
    Valve lifter guide hold-down bracket bolts
     
    Valve lifter guide hold-down brackets
     
    Valve lifter guides
     
    Valve lifters
     
    Charged air cooler
     
    A/C condenser
     
    Starter
     

  4.  
  5. Install the Flywheel Holding Tool No. J 44643 in the starter opening. Make sure the tool is flush to the flywheel opening. The holding tool will be used to remove the crankshaft balancer bolt and camshaft drive gear bolt.
    NOTE
    The crankshaft reluctor and oil pump drive gear are timed together at the factory. Do NOT remove the reluctor from the oil pump drive gear.



    Click image to see an enlarged view

    Fig. Proper installation of the flywheel holding tool in the starter opening-6.6L engines



    Engine front cover
     
    Oil pump driven gear nut and gear
     



    Oil pump drive gear and crankshaft reluctor assembly. Do not remove the reluctor bolts or damage the reluctor teeth
     

  6.  
  7. Using the Magnetic Base J 26900-13 and Dial Indicator J 26900-12, measure the camshaft end-play. The production value is 0.002-0.0045 in. (0.050-0.114mm) and the service limit is 0.008 in. (0.20mm). Replace the cam gear or thrust plate if the measured value exceeds the service limit.
    NOTE
    Use the flywheel holding tool to hold the engine from turning while loosening the camshaft gear bolt.



    Click image to see an enlarged view

    Fig. Use the dial indicator (1) and magnetic base (2) to measure the camshaft end-play-6.6L engines



    Camshaft reluctor screws and reluctor
     



    Loosen the camshaft gear bolt and leave the bolt finger-tight
     
    Camshaft thrust plate bolts through the holes in the camshaft gear
     
    Camshaft with the gear attached
     
    Cam gear bolt and gear
     
    Thrust plate
     

  8.  
  9. Clean and inspect the camshaft and bearings.
  10.  

To install:

  1. Install or connect the following:

    Camshaft thrust plate
     
    Camshaft driven gear
     
    New driven gear bolt (finger-tight)
     
    Camshaft and gear assembly into the cylinder block. Align the gear to the crankshaft gear

    Click image to see an enlarged view

    Fig. Camshaft and crankshaft gear alignment-6.6L engines

     



    Threadlock to the thrust plate bolts
     
    Thrust plate bolts and tighten to 19 ft. lbs. (26 Nm)
     
    Camshaft reluctor to the cam gear
     
    Reluctor bolts. Tighten to 80 inch lbs. (9 Nm) in a crisscross pattern.
     
    If removed, reinstall the flywheel holding tool in the starter opening
     
    Camshaft gear bolt and tighten to 173 ft. lbs. (234 Nm)
     

  2.  
  3. Using the Magnetic Base J 26900-13 and Dial Indicator J 26900-12, measure the camshaft end-play. Replace the cam gear or thrust plate if the measured value exceeds the service limit; refer to the Camshaft Specifications chart.

    Oil pump drive gear and reluctor to the crankshaft. Do not damage the teeth of the reluctor.
     
    Oil pump driven gear and nut. Tighten to 74 ft. lbs. (100 Nm).
     
    Engine front cover
     
    A/C condenser
     
    Charged air cooler
     

  4.  
  5. Apply clean engine oil to the roller and outside of the lifters.

    Valve lifters
     
    Valve lifter guides
     
    Valve lifter guide hold-down brackets. Make sure that both tabs of the bracket are in the holes of the valve lifter guides.
     
    Valve lifter guide hold-down bracket bolts. Tighten to 97 inch lbs. (11 Nm).
     

  6.  

7.4L Engines
  1. Drain the cooling system.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Properly discharge the air conditioning system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover (if equipped)
     
    Air cleaner assembly
     
    Grille and center support section, as required
     
    Air conditioning compressor, condenser and auxiliary fan, if equipped
     
    Fan, the shroud
     
    Radiator
     
    Accessory belt, as required
     
    Alternator, as required
     
    Valve covers
     
    Hoses from the water pump
     
    Water pump
     

  8.  
  9. Align the timing marks at Top Dead Center (TDC).

    Harmonic balancer and pulley
     
    Engine front cover
     

  10.  
  11. Mark the distributor rotor-to-housing location.

    Distributor assembly
     
    Intake manifold assembly
     
    Lifters, pushrods, and rocker arms
     

  12.  
  13. Rotate the camshaft so the timing marks align.

    Camshaft sprocket bolts
     
    Camshaft sprocket and timing
     
    Engine mount through-bolts
     

  14.  
  15. Install 2 or 3 5 / 16 -18 bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Install 2 or 3 long bolts into the camshaft to use as a handle for easy removal or installation-7.4L engine shown, other engines similar

  16.  

To install:

  1. Liberally coat camshaft and bearing with heavy engine oil or engine assembly lubricant
  2.  
  3. Align the timing marks on the camshaft sprocket and crankshaft gears.
  4.  
  5. Install or connect the following:

    Camshaft
     
    Camshaft sprocket and chain. Torque the bolts to 25 ft. lbs. (34 Nm)
     
    Engine mount bolts
     
    Lifters and pushrods and adjust the valves
     
    Intake manifold
     
    Distributor using the locating marks made during removal
     
    Engine front cover
     
    Harmonic balancer and pulley
     
    Water pump
     
    Hoses at the water pump
     
    Valve covers
     
    Alternator, if removed
     
    Accessory belt, if removed
     
    Fan shroud and radiator
     
    Air conditioning condenser and compressor
     
    Grille and center support, if removed
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system with the proper type and quantity of antifreeze.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Properly discharge the air conditioning system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Grille and center support section, as required
     
    Air conditioning compressor, condenser and auxiliary fan, if equipped
     
    Fan, the shroud
     
    Radiator
     
    Accessory belt, as required
     
    Alternator, as required
     
    Valve covers
     
    Hoses from the water pump
     
    Water pump
     

  10.  
  11. Align the timing marks at TDC.

    Harmonic balancer and pulley
     
    Engine front cover
     

  12.  
  13. Mark the distributor rotor-to-housing location.

    Distributor assembly
     
    Intake manifold assembly
     
    Lifters, pushrods, and rocker arms
     

  14.  
  15. Rotate the camshaft so the timing marks align.

    Camshaft sprocket bolts
     
    Camshaft sprocket and timing
     
    Engine mount through-bolts
     

  16.  
  17. Install 2 or 3 5 / 16 -18 bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Install 2 or 3 long bolts into the camshaft to use as a handle for easy removal or installation-7.4L engine shown, other engines similar

  18.  

To install:

  1. Liberally coat camshaft and bearing with heavy engine oil or engine assembly lubricant
  2.  
  3. Align the timing marks on the camshaft sprocket and crankshaft gears.
  4.  
  5. Install or connect the following:

    Camshaft
     
    Camshaft sprocket and chain. Torque the bolts to 25 ft. lbs. (34 Nm).
     
    Engine mount bolts
     
    Lifters and pushrods and adjust the valves
     
    Intake manifold
     
    Distributor using the locating marks made during removal
     
    Engine front cover
     
    Harmonic balancer and pulley
     
    Water pump
     
    Hoses at the water pump
     
    Valve covers
     
    Alternator, if removed
     
    Accessory belt, if removed
     
    Fan shroud and radiator
     
    Air conditioning condenser and compressor
     
    Grille and center support, if removed
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system with the proper type and quantity of antifreeze.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Properly discharge the air conditioning system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, on van models
     
    Air cleaner assembly
     
    Grille and center support section, as required
     
    Air conditioning compressor, condenser and auxiliary fan, if equipped
     
    Fan, the shroud
     
    Radiator
     
    Accessory belt, as required
     
    Alternator, as required
     
    Valve covers
     
    Hoses from the water pump
     
    Water pump
     

  10.  
  11. Align the timing marks at TDC.

    Harmonic balancer and pulley
     
    Engine front cover
     

  12.  
  13. Mark the distributor rotor-to-housing location.

    Distributor assembly
     
    Intake manifold assembly
     
    Lifters, pushrods, and rocker arms
     

  14.  
  15. Rotate the camshaft so the timing marks align.

    Camshaft sprocket bolts
     
    Camshaft sprocket and timing
     
    Engine mount through-bolts
     

  16.  
  17. Install 2 or 3 5 / 16 -18 bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.
  18.  

To install:

  1. Liberally coat camshaft and bearing with heavy engine oil or engine assembly lubricant
  2.  
  3. Align the timing marks on the camshaft sprocket and crankshaft gears.
  4.  
  5. Install or connect the following:

    Camshaft
     
    Camshaft sprocket and chain. Torque the bolts to 25 ft. lbs. (34 Nm)
     
    Engine mount bolts
     
    Lifters and pushrods and adjust the valves
     
    Intake manifold
     
    Distributor using the locating marks made during removal
     
    Engine front cover
     
    Harmonic balancer and pulley
     
    Water pump
     
    Hoses at the water pump
     
    Valve covers
     
    Alternator, if removed
     
    Accessory belt, if removed
     
    Fan shroud and radiator
     
    Air conditioning condenser and compressor
     
    Grille and center support, if removed
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system with the proper type and quantity of antifreeze.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Properly discharge the air conditioning system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover, on van models
     
    Air cleaner assembly
     
    Grille and center support section, as required
     
    Air conditioning compressor, condenser and auxiliary fan, if equipped
     
    Fan, the shroud
     
    Radiator
     
    Accessory belt, as required
     
    Alternator, as required
     
    Valve covers
     
    Hoses from the water pump
     
    Water pump
     

  10.  
  11. Align the timing marks at TDC.

    Harmonic balancer and pulley
     
    Engine front cover
     

  12.  
  13. Mark the distributor rotor-to-housing location.

    Distributor assembly
     
    Intake manifold assembly
     
    Lifters, pushrods, and rocker arms
     

  14.  
  15. Rotate the camshaft so the timing marks align.

    Camshaft sprocket bolts
     
    Camshaft sprocket and timing
     
    Engine mount through-bolts
     

  16.  
  17. Install 2 or 3 5 / 16 -18 bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.
  18.  

To install:

  1. Liberally coat camshaft and bearing with heavy engine oil or engine assembly lubricant
  2.  
  3. Align the timing marks on the camshaft sprocket and crankshaft gears.
  4.  
  5. Install or connect the following:

    Camshaft
     
    Camshaft sprocket and chain. Torque the bolts to 25 ft. lbs. (34 Nm)
     
    Engine mount bolts
     
    Lifters and pushrods and adjust the valves
     
    Intake manifold
     
    Distributor using the locating marks made during removal
     
    Engine front cover
     
    Harmonic balancer and pulley
     
    Water pump
     
    Hoses at the water pump
     
    Valve covers
     
    Alternator, if removed
     
    Accessory belt, if removed
     
    Fan shroud and radiator
     
    Air conditioning condenser and compressor
     
    Grille and center support, if removed
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system with the proper type and quantity of antifreeze.
  8.  

8.1L Engine
  1. Properly discharge the air conditioning system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If any lifters are stuck in their bores, use a suitable valve lifter to remove them.


    WARNING
    All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings.



    Grille
     
    A/C condenser
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Valve lifter guide retainer bolts and retainer
     
    Valve lifter guides, keeping them in proper order for reassembly
     
    Valve lifters
     
    Timing chain and sprocket
     
    Camshaft retaining bolts
     
    Camshaft retainer
     

  4.  
  5. Install three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Use the 3 bolts as a handle to carefully remove and install the camshaft-8.1L engine shown

  6.  
  7. Remove the bolts from the front of the camshaft.
  8.  
  9. Clean and inspect the camshaft for damage.
  10.  

To install:

  1. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant.
  2.  
  3. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts.
    NOTE
    If a new camshaft is installed, you MUST install new valve lifters.

  4.  
  5. Install or connect the following:

    Camshaft retainer and bolts. Tighten to 106 inch lbs. (12 Nm).
     
    Timing chain and sprocket
     
    Valve lifters
     
    Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes.
     
    Valve lifter guide retainer. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Rocker arms and pushrods
     
    Intake manifold
     
    A/C condenser
     
    Grille
     

  6.  
  7. Recharge the A/C system.
  8.  

  1. Properly discharge the air conditioning system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If any lifters are stuck in their bores, use a suitable valve lifter to remove them.


    WARNING
    All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings.



    Grille
     
    A/C condenser
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Valve lifter guide retainer bolts and retainer
     
    Valve lifter guides, keeping them in proper order for reassembly
     
    Valve lifters
     



    Timing chain and sprocket
     
    Camshaft retaining bolts
     
    Camshaft retainer
     

  4.  
  5. Install three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Use the 3 bolts as a handle to carefully remove and install the camshaft

  6.  
  7. Remove the bolts from the front of the camshaft.
  8.  
  9. Clean and inspect the camshaft for damage.
  10.  

To install:

  1. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant.
  2.  
  3. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts.
  4.  
  5. Install or connect the following:
    NOTE
    If a new camshaft is installed, you MUST install new valve lifters.



    Camshaft retainer and bolts. Tighten to 106 inch lbs. (12 Nm).
     



    Timing chain and sprocket
     
    Valve lifters
     
    Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes.
     
    Valve lifter guide retainer and tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Rocker arms and pushrods
     
    Intake manifold
     
    A/C condenser
     
    Grille
     

  6.  
  7. Recharge the A/C system.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly discharge the air conditioning system.
    NOTE
    If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  4.  
  5. Remove or disconnect the following:
    NOTE
    If any lifters are stuck in their bores, use a suitable valve lifter to remove them.


    WARNING
    All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings.



    Grille
     
    A/C condenser
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Valve lifter guide retainer bolts and retainer
     
    Valve lifter guides, keeping them in proper order for reassembly
     
    Valve lifters
     



    Timing chain and sprocket
     
    Camshaft retaining bolts
     
    Camshaft retainer
     

  6.  
  7. Install three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Use the 3 bolts as a handle to carefully remove and install the camshaft

  8.  
  9. Remove the bolts from the front of the camshaft.
  10.  
  11. Clean and inspect the camshaft for damage.
  12.  

To install:

  1. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant.
  2.  
  3. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts.
  4.  
  5. Install or connect the following:
    NOTE
    If a new camshaft is installed, you MUST install new valve lifters.



    Camshaft retainer and bolts. Tighten to 106 inch lbs. (12 Nm)
     



    Timing chain and sprocket
     
    Valve lifters
     
    Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes
     
    Valve lifter guide retainer. Tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Rocker arms and pushrods
     
    Intake manifold
     
    A/C condenser
     
    Grille
     

  6.  
  7. Recharge the A/C system.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly discharge the air conditioning system.
    NOTE
    If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  4.  
  5. Remove or disconnect the following:
    NOTE
    If any lifters are stuck in their bores, use a suitable valve lifter to remove them.


    WARNING
    All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings.



    Grille
     
    A/C condenser
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Valve lifter guide retainer bolts and retainer
     
    Valve lifter guides, keeping them in proper order for reassembly
     
    Valve lifters
     



    Timing chain and sprocket
     
    Camshaft retaining bolts
     
    Camshaft retainer
     

  6.  
  7. Install three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Use the 3 bolts as a handle to carefully remove and install the camshaft

  8.  
  9. Remove the bolts from the front of the camshaft.
  10.  
  11. Clean and inspect the camshaft for damage.
  12.  

To install:

  1. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant.
  2.  
  3. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts.
  4.  
  5. Install or connect the following:
    NOTE
    If a new camshaft is installed, you MUST install new valve lifters.



    Camshaft retainer and bolts. Tighten to 106 inch lbs. (12 Nm)
     



    Timing chain and sprocket
     
    Valve lifters
     
    Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes
     
    Valve lifter guide retainer. Tighten the bolts to 18 ft. lbs. (25 Nm)
     
    Rocker arms and pushrods
     
    Intake manifold
     
    A/C condenser
     
    Grille
     

  6.  
  7. Recharge the A/C system.
  8.  

  1. Properly discharge the air conditioning system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If any lifters are stuck in their bores, use a suitable valve lifter to remove them.


    WARNING
    All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings.



    Grille
     
    A/C condenser
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Valve lifter guide retainer bolts and retainer
     
    Valve lifter guides, keeping them in proper order for reassembly
     
    Valve lifters
     
    Timing chain and sprocket
     
    Camshaft retaining bolts
     
    Camshaft retainer
     

  4.  
  5. Install three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Use the 3 bolts as a handle to carefully remove and install the camshaft-8.1L engines

  6.  
  7. Remove the bolts from the front of the camshaft.
  8.  
  9. Clean and inspect the camshaft for damage.
  10.  

To install:

  1. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant.
  2.  
  3. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts.
    NOTE
    If a new camshaft is installed, you MUST install new valve lifters.

  4.  
  5. Install or connect the following:

    Camshaft retainer and bolts. Tighten to 106 inch lbs. (12 Nm).
     
    Timing chain and sprocket
     
    Valve lifters
     
    Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes.
     
    Valve lifter guide retainer. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Rocker arms and pushrods
     
    Intake manifold
     
    A/C condenser
     
    Grille
     

  6.  
  7. Recharge the A/C system.
  8.  

  1. Properly discharge the air conditioning system.
  2.  
  3. Remove or disconnect the following:
    NOTE
    If any lifters are stuck in their bores, use a suitable valve lifter to remove them.


    WARNING
    All of the cam journals are the same size so be very careful when removing and installing the camshaft that you do not damage the bearings.



    Grille
     
    A/C condenser
     
    Intake manifold
     
    Rocker arms and pushrods
     
    Valve lifter guide retainer bolts and retainer
     
    Valve lifter guides, keeping them in proper order for reassembly
     
    Valve lifters
     
    Timing chain and sprocket
     
    Camshaft retaining bolts
     
    Camshaft retainer
     

  4.  
  5. Install three 8-1.25 x 100mm bolts in the holes in the front of the camshaft and carefully pull the camshaft from the block.

    Click image to see an enlarged view

    Fig. Use the 3 bolts as a handle to carefully remove and install the camshaft-8.1L engines

  6.  
  7. Remove the bolts from the front of the camshaft.
  8.  
  9. Clean and inspect the camshaft for damage.
  10.  

To install:

  1. Liberally coat camshaft and bearings with heavy engine oil or engine assembly lubricant.
  2.  
  3. Install the camshaft, using the 3 bolts threaded into the camshaft bolt holes as a handle, then remove the bolts.
    NOTE
    If a new camshaft is installed, you MUST install new valve lifters.

  4.  
  5. Install or connect the following:

    Camshaft retainer and bolts. Tighten to 106 inch lbs. (12 Nm).
     
    Timing chain and sprocket
     
    Valve lifters
     
    Valve lifter guides over the flats on the lifters. Make sure the rollers of the lifters are properly aligned with the cam lobes.
     
    Valve lifter guide retainer. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    Rocker arms and pushrods
     
    Intake manifold
     
    A/C condenser
     
    Grille
     

  6.  
  7. Recharge the A/C system.
  8.  

 
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