Infiniti Car 1998-05

Camshaft, Bearings & Lifters 2

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Oil separator
     

  6.  
  7. Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) on the compression stroke and the mating marks on the camshaft sprockets line up with the mating marks on the timing chain.

    Timing chain tensioner
     


    Click image to see an enlarged view

    Fig. Be sure to align the marks on the sprockets with the marks on the chain-2.0L engine

    Distributor
     
    Timing chain guide
     
    Camshaft sprockets. Use a wrench to hold the camshaft while loosening the sprocket bolt.
     

  8.  
  9. Loosen the camshaft bearing cap bolts in sequence.

    Camshaft from the cylinder head
     

  10.  
  11. When removing the rocker arm, be careful not to drop the valve shims into the cylinder head. After removing the adjuster, set them upright or lay them down in a pan of clean engine oil. Do not lay them down on the bench or the oil will drain out and the adjuster will become air bound. Keep all of these parts in order so they can be installed in the same locations.
  12.  


    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt loosening sequence-2.0L engine


To install:

  1. Install the adjusters, shims and rockers into their original locations.
  2.  
  3. Clean the left-hand camshaft end bearing cap and coat the mating surface with liquid gasket. Install the camshafts, bearing caps, oil tubes and baffle plate. Ensure the left camshaft key is at 12 o'clock and the right camshaft key is at 10 o'clock.
  4.  
  5. The procedure for tightening bearing cap bolts must be followed exactly to prevent camshaft damage. Torque bolts as follows:
    1. Torque the right camshaft bolts 9 and 10 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 8 (in that order) to the same specification.
    2.  
    3. Torque the left camshaft bolts 11 and 12 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 10 (in that order) to the same specification.
    4.  
    5. Torque all bolts in sequence to 52 inch lbs. (6 Nm).
    6.  
    7. Torque all bolts again in sequence to 78-102 inch lbs. (9-12 Nm), then bolts 8 and 9 on the left camshaft to 13-19 ft. lbs. (18-25 Nm).
    8.  

  6.  
  7. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Torque sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  8.  
  9. Install or connect the following:

    Timing chain guide and chain tensioner
     
    Distributor making certain that the rotor head is at the 5 o'clock position
     

  10.  
  11. Clean the rocker cover and mating surfaces and apply a continuous bead of liquid gasket to the mating surface.
  12.  
  13. Install the rocker cover and oil separator. Tighten the rocker cover bolts as follows:
    1. Torque the nuts 1, 10, 11 and 8, in that order to 36 inch lbs. (4 Nm).
    2.  
    3. Torque the nuts 1 through 13 as indicated in the figure to 72-84 inch lbs. (8-10 Nm).
    4.  

  14.  
  15. Connect the negative battery cable.
  16.  


    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt torque sequence-2.0L engine


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Oil separator
     
    Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) on the compression stroke and the mating marks on the camshaft sprockets line up with the mating marks on the timing chain
     
    Timing chain tensioner

    Click image to see an enlarged view

    Fig. Be sure to align the marks on the sprockets with the marks on the chain-2.0L engine

     



    Distributor
     
    Timing chain guide
     
    Camshaft sprockets. Use a wrench to hold the camshaft while loosening the sprocket bolt
     

  6.  
  7. Loosen the camshaft bearing cap bolts in sequence.

    Camshaft from the cylinder head
     

  8.  
  9. When removing the rocker arm, be careful not to drop the valve shims into the cylinder head. After removing the adjuster, set them upright or lay them down in a pan of clean engine oil. Do not lay them down on the bench or the oil will drain out and the adjuster will become air bound. Keep all of these parts in order so they can be installed in the same locations.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt loosening sequence-2.0L engine

  10.  

To install:

  1. Install the adjusters, shims and rockers into their original locations.
  2.  
  3. Clean the left-hand camshaft end bearing cap and coat the mating surface with liquid gasket. Install the camshafts, bearing caps, oil tubes and baffle plate. Ensure the left camshaft key is at 12 o'clock and the right camshaft key is at 10 o'clock.
  4.  
  5. The procedure for tightening bearing cap bolts must be followed exactly to prevent camshaft damage. Torque bolts as follows:
    1. Torque the right camshaft bolts 9 and 10 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 8 (in that order) to the same specification.
    2.  
    3. Torque the left camshaft bolts 11 and 12 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 10 (in that order) to the same specification.
    4.  
    5. Torque all bolts in sequence to 52 inch lbs. (6 Nm).
    6.  
    7. Torque all bolts again in sequence to 78-102 inch lbs. (9-12 Nm), then bolts 8 and 9 on the left camshaft to 13-19 ft. lbs. (18-25 Nm).
    8.  

  6.  
  7. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Torque sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  8.  
  9. Install or connect the following:

    Timing chain guide and chain tensioner
     
    Distributor making certain that the rotor head is at the 5 o'clock position

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt torque sequence-2.0L engine

     

  10.  
  11. Clean the rocker cover and mating surfaces and apply a continuous bead of liquid gasket to the mating surface.
  12.  
  13. Install the rocker cover and oil separator. Tighten the rocker cover bolts as follows:
    1. Torque the nuts 1, 10, 11 and 8, in that order to 36 inch lbs. (4 Nm).
    2.  
    3. Torque the nuts 1 through 13 as indicated in the figure to 72-84 inch lbs. (8-10 Nm).
    4.  

  14.  
  15. Connect the negative battery cable.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Oil separator
     
    Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) on the compression stroke and the mating marks on the camshaft sprockets line up with the mating marks on the timing chain
     
    Timing chain tensioner

    Click image to see an enlarged view

    Fig. Be sure to align the marks on the sprockets with the marks on the chain-1998-2001 2.0L engine

     



    Distributor
     
    Timing chain guide
     
    Camshaft sprockets. Use a wrench to hold the camshaft while loosening the sprocket bolt
     

  6.  
  7. Loosen the camshaft bearing cap bolts in sequence.

    Camshaft from the cylinder head
     

  8.  
  9. When removing the rocker arm, be careful not to drop the valve shims into the cylinder head. After removing the adjuster, set them upright or lay them down in a pan of clean engine oil. Do not lay them down on the bench or the oil will drain out and the adjuster will become air bound. Keep all of these parts in order so they can be installed in the same locations.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt loosening sequence-1998-2001 2.0L engine

  10.  

To install:

  1. Install the adjusters, shims and rockers into their original locations.
  2.  
  3. Clean the left-hand camshaft end bearing cap and coat the mating surface with liquid gasket. Install the camshafts, bearing caps, oil tubes and baffle plate. Ensure the left camshaft key is at 12 o'clock and the right camshaft key is at 10 o'clock.
  4.  
  5. The procedure for tightening bearing cap bolts must be followed exactly to prevent camshaft damage. Torque bolts as follows:
    1. Torque the right camshaft bolts 9 and 10 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 8 (in that order) to the same specification.
    2.  
    3. Torque the left camshaft bolts 11 and 12 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 10 (in that order) to the same specification.
    4.  
    5. Torque all bolts in sequence to 52 inch lbs. (6 Nm).
    6.  
    7. Torque all bolts again in sequence to 78-102 inch lbs. (9-12 Nm), then bolts 8 and 9 on the left camshaft to 13-19 ft. lbs. (18-25 Nm).
    8.  

  6.  
  7. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Torque sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  8.  
  9. Install or connect the following:

    Timing chain guide and chain tensioner
     
    Distributor making certain that the rotor head is at the 5 o'clock position

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt torque sequence-1998-2001 2.0L engine

     

  10.  
  11. Clean the rocker cover and mating surfaces and apply a continuous bead of liquid gasket to the mating surface.
  12.  
  13. Install the rocker cover and oil separator. Tighten the rocker cover bolts as follows:
    1. Torque the nuts 1, 10, 11 and 8, in that order to 36 inch lbs. (4 Nm).
    2.  
    3. Torque the nuts 1 through 13 as indicated in the figure to 72-84 inch lbs. (8-10 Nm).
    4.  

  14.  
  15. Connect the negative battery cable.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Rocker arm cover
     
    Oil separator
     

  6.  
  7. Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) on the compression stroke and the mating marks on the camshaft sprockets line up with the mating marks on the timing chain.

    Timing chain tensioner

    Click image to see an enlarged view

    Fig. Be sure to align the marks on the sprockets with the marks on the chain-2.0L engine

     
    Distributor
     
    Timing chain guide
     
    Camshaft sprockets. Use a wrench to hold the camshaft while loosening the sprocket bolt.
     

  8.  
  9. Loosen the camshaft bearing cap bolts in sequence.

    Camshaft from the cylinder head
     

  10.  
  11. When removing the rocker arm, be careful not to drop the valve shims into the cylinder head. After removing the adjuster, set them upright or lay them down in a pan of clean engine oil. Do not lay them down on the bench or the oil will drain out and the adjuster will become air bound. Keep all of these parts in order so they can be installed in the same locations.

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt loosening sequence-2.0L engines

  12.  

To install:

  1. Install the adjusters, shims and rockers into their original locations.
  2.  
  3. Clean the left-hand camshaft end bearing cap and coat the mating surface with liquid gasket. Install the camshafts, bearing caps, oil tubes and baffle plate. Ensure the left camshaft key is at 12 o'clock and the right camshaft key is at 10 o'clock.
  4.  
  5. The procedure for tightening bearing cap bolts must be followed exactly to prevent camshaft damage. Torque bolts as follows:
    1. STEP 1: Intake camshaft, tighten bolts 9 - 10 in that order then tighten bolts 1-8 in numerical order to 2 Nm (17 inch lbs.); Exhaust camshaft, tighten bolts 11-12 in that order then tighten bolts 1-10 in numerical order to 2 Nm (17 inch lbs.)
    2.  
    3. STEP 2: Tighten all bolts in the specified order to 6 Nm (52 inch lbs.)
    4.  
    5. STEP 3: Tighten all bolts in the specified order to

      Bolt type A B: 10-12 Nm (86-104 inch lbs.)
       
      Bolt type C: 18-25 Nm (13-19 ft. lbs.)
       

    6.  

  6.  
  7. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Torque sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  8.  
  9. Install or connect the following:

    Timing chain guide and chain tensioner
     
    Distributor making certain that the rotor head is at the 5 o'clock position

    Click image to see an enlarged view

    Fig. Camshaft bearing cap bolt torque sequence-2.0L engines

     

  10.  
  11. Clean the rocker cover and mating surfaces and apply a continuous bead of liquid gasket to the mating surface.
  12.  
  13. Install the rocker cover and oil separator. Tighten the rocker cover bolts as follows:
    1. Torque the nuts 1, 10, 11 and 8, in that order to 36 inch lbs. (4 Nm).
    2.  
    3. Torque the nuts 1 through 13 as indicated in the figure to 72-84 inch lbs. (8-10 Nm).
    4.  

  14.  
  15. Connect the negative battery cable.
  16.  

3.0L & 3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Left side rocker cover ornament
     

  10.  


NOTE
Before disconnecting any hoses or connectors, note the locations for reassembly.



Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
 
Fuel hoses and disconnect the harness connection
 
Evaporative emissions (EVAP) canister purge hoses
 
Water hoses from the cylinder head and intake manifold
 
Ignition coils
 
Spark plugs
 
Exhaust Gas Recirculation (EGR) tube
 
Intake manifold collector supports and the collector
 


Click image to see an enlarged view

Fig. To avoid camshaft damage, loosen the bearing cap bolts in the sequence shown-3.0L and 3.5L engines, except G35

Fuel tube
 
Intake manifold
 
Rocker arm covers
 
Engine undercovers
 
Right front wheel
 
Engine side covers
 
Drive belts and idler pulley
 
Power steering oil pump and belt
 
Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
 

  1. Set the No. 1 piston to Top Dead center (TDC) of compression stroke by rotating the crankshaft.

    Ring gear cover access plate
     

  2.  
  3. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate.
  4.  


NOTE
Use care not to damage the ring gear teeth.



Crankshaft pulley, using a suitable puller
 
A/C compressor and bracket
 
Front exhaust pipe and install engine slingers
 

  1. Support the transaxle with jack.

    Right side engine mounting bracket
     
    Center crossmember assembly
     
    Oil pan bolts and oil pans
     
    Timing chain
     
    O-rings from the front of the engine block
     

  2.  
  3. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
  4.  


NOTE
Keep all bearing caps and camshafts in proper order for reinstallation.



Left-hand and right-hand camshaft tensioners from the cylinder head
 
Camshafts from the cylinder heads
 


NOTE
The valve adjusters have a replaceable shim on the top of the adjuster. Note the proper locations of each shim to adjuster and remove the shims from the adjusters.



Valve adjusting shim from the adjuster, using a magnet
 
Adjuster assembly from the bore. Be sure to note the locations from where each adjuster came.
 

  1. Check the diameter of the valve adjuster and the valve adjuster guide bore.
  2.  
  3. The diameter of the adjuster should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021mm).

    All traces of liquid gasket from the timing chain case and from the water pump covers
     
    All traces of liquid gasket from the engine block
     

  4.  
  5. Inspect the camshafts for excessive wear or damage and replace as necessary.
  6.  

To install:

  1. Lubricate the valve adjusters with clean engine oil and install the adjusters into the bore from which they were removed.
  2.  
  3. Lubricate the valve adjuster shims with clean engine oil and install the shims into the adjuster from which they were removed.
  4.  
  5. Turn the crankshaft clockwise until the No. 1 piston is set 240° before TDC on compression stroke.
  6.  
  7. Install or connect the following:

    Camshaft tensioners on both sides of the cylinder heads. Torque the tensioner mounting bolts to 75-96 inch lbs. (8-11 Nm).
     

  8.  


NOTE
The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark. When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



Click image to see an enlarged view

Fig. Positioning of the camshaft keys during installation-3.0L and 3.5L engines, except G35



Exhaust and intake camshafts and install the bearing caps. Before installing the No. 1 bearing cap, apply liquid gasket to the corners of the cap.
 

  1. Torque the camshaft bearing caps as follows:
    1. Nos. 7 through 10 then, Nos. 1 through 6 to 17 inch lbs. (2 Nm).
    2.  
    3. All bolts in order to 52 inch lbs. (6 Nm).
    4.  
    5. Nos. 1 though 6 to 80-104 inch lbs. (9-11 Nm).
    6.  
    7. Nos. 7 though 10 to 74-91 inch lbs. (9-11 Nm).
    8.  



    Click image to see an enlarged view

    Fig. Be sure to tighten the camshaft bearing cap bolts in the correct sequence-3.0L and 3.5L engines (except G35), right cylinder head



    Click image to see an enlarged view

    Fig. Tighten the camshaft bearing cap bolts in the correct sequence-3.0L and 3.5L engines (except G35), left cylinder head



    New O-rings to the front of the engine block
     

  2.  
  3. Apply sealant to the hatched portion of the of the rear timing chain case.
  4.  
  5. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).

    Crankshaft sprocket with the mating mark facing out
     

  6.  
  7. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head

    Lower chain guide on the dowel pin with the front mark on the guide facing upward
     

  8.  
  9. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.

    Exhaust camshaft sprockets onto the dowel pin. Torque the bolts to 88-95 ft. lbs. (120-129 Nm). Be sure to secure the camshafts while tightening the bolts.
     
    Align and install the timing chains and sprockets to the camshafts
     
    Timing cover evenly and gently. Be sure to align the dowel pin holes
     

  10.  


NOTE
Leave the bolts unattended for 30 minutes or more after tightening.

  1. Apply a 0.091-0.130 in. (2.3-3.3mm) continuous bead of liquid gasket to the water pump cover and install the cover. Tighten the bolts to 84-108 inch lbs. (10-13 Nm).

    Rocker covers
     

  2.  
  3. Apply sealant to the front and rear seal of the oil pan and install the oil pan.

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     
    Engine slinger assembly
     
    Front exhaust pipe and its support
     
    Air conditioning compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt
     

  4.  
  5. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another.

    Ring gear cover plate
     
    CMP sensor (PHASE) and CKP sensors
     
    Power steering pump assembly, drive belts and the idler pulley
     
    Engine side cover
     
    Right front wheel
     
    Engine undercovers
     
    Intake manifold, using new gaskets
     
    Fuel tube assembly using new insulators. Torque the bolts in several steps to 15-20 ft. lbs. (21-26 Nm).
     
    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector assembly and support bracket
     
    EGR tube using new insulators. Torque the bolts in two steps to 15-20 ft. lbs. (21-26 Nm).
     
    Spark plugs and ignition coils. Torque the bolts to 27-33 inch lbs. (2.9-3.8 Nm).
     
    Water hoses to the cylinder head and intake manifold
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Fill and bleed the cooling system.
  10.  
  11. Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil and cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Front timing chain case
     
    Camshaft sprocket
     
    Timing chain
     
    Rear timing chain case
     
    Camshaft Position (CMP) sensors (PHASE) from the back side of the cylinder heads
     
    Intake valve timing control solenoid valves from the No. 1 camshaft bracket
     

  8.  


    Click image to see an enlarged view

    Fig. Location of the intake valve timing control solenoid valves-G35 models



NOTE
Before removal, matchmark the position of the camshafts, brackets and bolts, so they are reinstalled in their original locations.



Intake and exhaust camshaft brackets. Loosen the bolts in several stages, in reverse of the sequence shown.
 


Click image to see an enlarged view

Fig. Intake and exhaust camshaft bracket bolts tightening sequence. Use the reverse sequence for removal-G35 models

Camshafts
 
Valve lifters if necessary, noting their installed positions
 

To install:

  1. Install or connect the following:

    Valve lifters, in their original positions
     
    Camshafts with the dowel pin attached to its front end face on the exhaust side
     


    Click image to see an enlarged view

    Fig. Camshaft identification and installation-G35 models

    Camshaft brackets, as shown in the illustration
     

  2.  
  3. Torque the camshaft bracket bolts, in sequence, as follows:
    1. Step 1: Nos. 7-10, then Nos. 1-6 to 17 inch lbs. (2 Nm).
    2.  
    3. Step 2: Nos. 1-10 to 52 inch lbs. (5.9 Nm).
    4.  
    5. Step 3: Nos. 1-6 to 80-104 inch lbs. (9-12 Nm).
    6.  
    7. Step 4: Nos. 7-10 to 74-91 inch lbs.
    8.  

  4.  
  5. Measure the difference in levels between the front end faces of the No. 1 camshaft bracket and the cylinder head. If the measurement falls out of the range of -0.0055-0.0055 in. (-0.14-0.14mm), you must reinstall the camshaft and brackets.
  6.  
  7. Check and adjust the valve clearance.

    Intake valve timing control solenoid valves
     
    CMP sensors (PHASE)
     
    Rear timing chain case, timing chain, camshaft sprocket and front timing chain case
     
    Negative battery cable
     

  8.  
  9. Fill the engine with oil.
  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  


    Click image to see an enlarged view

    Fig. Camshaft bracket installation-G35 models


3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Before disconnecting any hoses or connectors, note the locations for reassembly.



    Negative battery cable
     
    Left side rocker cover ornament
     



    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and disconnect the harness connection
     
    Evaporative emissions (EVAP) canister purge hoses
     
    Water hoses from the cylinder head and intake manifold
     
    Ignition coils
     
    Spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Intake manifold collector supports and the collector

    Click image to see an enlarged view

    Fig. To avoid camshaft damage, loosen the bearing cap bolts in the sequence shown-3.0L engine

     
    Fuel tube
     
    Intake manifold
     
    Rocker arm covers
     
    Engine undercovers
     
    Right front wheel
     
    Engine side covers
     
    Drive belts and idler pulley
     
    Power steering oil pump and belt
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
     

  10.  
  11. Set the No. 1 piston to Top Dead center (TDC) of compression stroke by rotating the crankshaft.

    Ring gear cover access plate
     

  12.  
  13. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate.
    NOTE
    Use care not to damage the ring gear teeth.



    Crankshaft pulley, using a suitable puller
     
    A/C compressor and bracket
     
    Front exhaust pipe and install engine slingers
     

  14.  
  15. Support the transaxle with jack.

    Right side engine mounting bracket
     
    Center crossmember assembly
     
    Oil pan bolts and oil pans
     
    Timing chain
     
    O-rings from the front of the engine block
     

  16.  
  17. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
    NOTE
    Keep all bearing caps and camshafts in proper order for reinstallation.


    NOTE
    The valve adjusters have a replaceable shim on the top of the adjuster. Note the proper locations of each shim to adjuster and remove the shims from the adjusters.



    Left-hand and right-hand camshaft tensioners from the cylinder head
     
    Camshafts from the cylinder heads
     



    Valve adjusting shim from the adjuster, using a magnet
     
    Adjuster assembly from the bore. Be sure to note the locations from where each adjuster came
     

  18.  
  19. Check the diameter of the valve adjuster and the valve adjuster guide bore.
  20.  
  21. The diameter of the adjuster should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021mm).

    All traces of liquid gasket from the timing chain case and from the water pump covers
     
    All traces of liquid gasket from the engine block
     

  22.  
  23. Inspect the camshafts for excessive wear or damage and replace as necessary.
  24.  

To install:

  1. Lubricate the valve adjusters with clean engine oil and install the adjusters into the bore from which they were removed.
  2.  
  3. Lubricate the valve adjuster shims with clean engine oil and install the shims into the adjuster from which they were removed.
  4.  
  5. Turn the crankshaft clockwise until the No. 1 piston is set 240° before TDC on compression stroke.
  6.  
  7. Install or connect the following:
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark. When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



    Camshaft tensioners on both sides of the cylinder heads. Torque the tensioner mounting bolts to 75-96 inch lbs. (8-11 Nm)
     



    Click image to see an enlarged view

    Fig. Positioning of the camshaft keys during installation-3.0L engine



    Exhaust and intake camshafts and install the bearing caps. Before installing the No. 1 bearing cap, apply liquid gasket to the corners of the cap
     

  8.  
  9. Torque the camshaft bearing caps as follows:
    1. Nos. 7 through 10 then, Nos. 1 through 6 to 17 inch lbs. (2 Nm).
    2.  
    3. All bolts in order to 52 inch lbs. (6 Nm).
    4.  
    5. All bolts in order to 80-104 inch lbs. (9-11 Nm).

      Click image to see an enlarged view

      Fig. Be sure to tighten the camshaft bearing cap bolts in the correct sequence-3.0L engine, right cylinder head



      Click image to see an enlarged view

      Fig. Tighten the camshaft bearing cap bolts in the correct sequence-3.0L engine, left cylinder head



      New O-rings to the front of the engine block
       

    6.  

  10.  
  11. Apply sealant to the hatched portion of the of the rear timing chain case.


  12.  
  13. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).

    Crankshaft sprocket with the mating mark facing out
     

  14.  
  15. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head

    Lower chain guide on the dowel pin with the front mark on the guide facing upward
     

  16.  
  17. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
    NOTE
    Leave the bolts unattended for 30 minutes or more after tightening.



    Exhaust camshaft sprockets onto the dowel pin. Torque the bolts to 88-95 ft. lbs. (120-129 Nm). Be sure to secure the camshafts while tightening the bolts
     
    Align and install the timing chains and sprockets to the camshafts
     
    Timing cover evenly and gently. Be sure to align the dowel pin holes
     

  18.  
  19. Apply a 0.091-0.130 in. (2.3-3.3mm) continuous bead of liquid gasket to the water pump cover and install the cover. Tighten the bolts to 84-108 inch lbs. (10-13 Nm).

    Rocker covers
     

  20.  
  21. Apply sealant to the front and rear seal of the oil pan and install the oil pan.

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     
    Engine slinger assembly
     
    Front exhaust pipe and its support
     
    Air conditioning compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt
     
    Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another
     
    Ring gear cover plate
     
    CMP sensor (PHASE) and CKP sensors (REF)/(POS)
     
    Power steering pump assembly, drive belts and the idler pulley
     
    Engine side cover
     
    Right front wheel
     
    Engine undercovers
     

  22.  
  23. Using new gaskets, install the intake manifold. Torque the bolts in 2 stages as follows:
    1. 44-86 inch lbs. (5-10 Nm).
    2.  
    3. 16-18 ft. lbs. (22-25 Nm).
    4.  

  24.  
  25. Install or connect the following:

    Fuel tube assembly using new insulators. Torque the bolts in several steps to 15-20 ft. lbs. (21-26 Nm).
     
    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector assembly and support bracket. Torque the bolts to 16-18 ft. lbs. (22-25 Nm)
     
    EGR tube using new insulators. Torque the bolts in two steps to 15-20 ft. lbs. (21-26 Nm).
     
    Spark plugs and ignition coils. Torque the bolts to 27-33 inch lbs. (2.9-3.8 Nm)
     
    Water hoses to the cylinder head and intake manifold
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  26.  
  27. Fill the engine with clean oil.
  28.  
  29. Fill and bleed the cooling system.
  30.  
  31. Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  32.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Before disconnecting any hoses or connectors, note the locations for reassembly.



    Negative battery cable
     
    Left side rocker cover ornament
     



    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Fuel hoses and disconnect the harness connection
     
    Evaporative emissions (EVAP) canister purge hoses
     
    Water hoses from the cylinder head and intake manifold
     
    Ignition coils
     
    Spark plugs
     
    Exhaust Gas Recirculation (EGR) tube
     
    Intake manifold collector supports and the collector

    Click image to see an enlarged view

    Fig. To avoid camshaft damage, loosen the bearing cap bolts in the sequence shown-3.0L engine

     
    Fuel tube
     
    Intake manifold
     
    Rocker arm covers
     
    Engine undercovers
     
    Right front wheel
     
    Engine side covers
     
    Drive belts and idler pulley
     
    Power steering oil pump and belt
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
     

  10.  
  11. Set the No. 1 piston to Top Dead center (TDC) of compression stroke by rotating the crankshaft.

    Ring gear cover access plate
     

  12.  
  13. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate.
    NOTE
    Use care not to damage the ring gear teeth.



    Crankshaft pulley, using a suitable puller
     
    A/C compressor and bracket
     
    Front exhaust pipe and install engine slingers
     

  14.  
  15. Support the transaxle with jack.

    Right side engine mounting bracket
     
    Center crossmember assembly
     
    Oil pan bolts and oil pans
     
    Timing chain
     
    O-rings from the front of the engine block
     

  16.  
  17. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
    NOTE
    Keep all bearing caps and camshafts in proper order for reinstallation.


    NOTE
    The valve adjusters have a replaceable shim on the top of the adjuster. Note the proper locations of each shim to adjuster and remove the shims from the adjusters.



    Left-hand and right-hand camshaft tensioners from the cylinder head
     
    Camshafts from the cylinder heads
     



    Valve adjusting shim from the adjuster, using a magnet
     
    Adjuster assembly from the bore. Be sure to note the locations from where each adjuster came
     

  18.  
  19. Check the diameter of the valve adjuster and the valve adjuster guide bore.
  20.  
  21. The diameter of the adjuster should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021mm).

    All traces of liquid gasket from the timing chain case and from the water pump covers
     
    All traces of liquid gasket from the engine block
     

  22.  
  23. Inspect the camshafts for excessive wear or damage and replace as necessary.
  24.  

To install:

  1. Lubricate the valve adjusters with clean engine oil and install the adjusters into the bore from which they were removed.
  2.  
  3. Lubricate the valve adjuster shims with clean engine oil and install the shims into the adjuster from which they were removed.
  4.  
  5. Turn the crankshaft clockwise until the No. 1 piston is set 240° before TDC on compression stroke.
  6.  
  7. Install or connect the following:
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark. When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



    Camshaft tensioners on both sides of the cylinder heads. Torque the tensioner mounting bolts to 75-96 inch lbs. (8-11 Nm)
     



    Click image to see an enlarged view

    Fig. Positioning of the camshaft keys during installation-3.0L engine



    Exhaust and intake camshafts and install the bearing caps. Before installing the No. 1 bearing cap, apply liquid gasket to the corners of the cap
     

  8.  
  9. Torque the camshaft bearing caps as follows:
    1. Nos. 7 through 10 then, Nos. 1 through 6 to 17 inch lbs. (2 Nm).
    2.  
    3. All bolts in order to 52 inch lbs. (6 Nm).
    4.  
    5. All bolts in order to 80-104 inch lbs. (9-11 Nm).

      Click image to see an enlarged view

      Fig. Be sure to tighten the camshaft bearing cap bolts in the correct sequence-3.0L engine, right cylinder head



      Click image to see an enlarged view

      Fig. Tighten the camshaft bearing cap bolts in the correct sequence-3.0L engine, left cylinder head



      New O-rings to the front of the engine block
       

    6.  

  10.  
  11. Apply sealant to the hatched portion of the of the rear timing chain case.


  12.  
  13. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).

    Crankshaft sprocket with the mating mark facing out
     

  14.  
  15. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head

    Lower chain guide on the dowel pin with the front mark on the guide facing upward
     

  16.  
  17. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
    NOTE
    Leave the bolts unattended for 30 minutes or more after tightening.



    Exhaust camshaft sprockets onto the dowel pin. Torque the bolts to 88-95 ft. lbs. (120-129 Nm). Be sure to secure the camshafts while tightening the bolts
     
    Align and install the timing chains and sprockets to the camshafts
     
    Timing cover evenly and gently. Be sure to align the dowel pin holes
     

  18.  
  19. Apply a 0.091-0.130 in. (2.3-3.3mm) continuous bead of liquid gasket to the water pump cover and install the cover. Tighten the bolts to 84-108 inch lbs. (10-13 Nm).

    Rocker covers
     

  20.  
  21. Apply sealant to the front and rear seal of the oil pan and install the oil pan.

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     
    Engine slinger assembly
     
    Front exhaust pipe and its support
     
    Air conditioning compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt
     
    Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another
     
    Ring gear cover plate
     
    CMP sensor (PHASE) and CKP sensors (REF)/(POS)
     
    Power steering pump assembly, drive belts and the idler pulley
     
    Engine side cover
     
    Right front wheel
     
    Engine undercovers
     

  22.  
  23. Using new gaskets, install the intake manifold. Torque the bolts in 2 stages as follows:
    1. 44-86 inch lbs. (5-10 Nm).
    2.  
    3. 16-18 ft. lbs. (22-25 Nm).
    4.  

  24.  
  25. Install or connect the following:

    Fuel tube assembly using new insulators. Torque the bolts in several steps to 15-20 ft. lbs. (21-26 Nm).
     
    Intake manifold collector gasket with the arrow facing forward
     
    Intake manifold collector assembly and support bracket. Torque the bolts to 16-18 ft. lbs. (22-25 Nm)
     
    EGR tube using new insulators. Torque the bolts in two steps to 15-20 ft. lbs. (21-26 Nm).
     
    Spark plugs and ignition coils. Torque the bolts to 27-33 inch lbs. (2.9-3.8 Nm)
     
    Water hoses to the cylinder head and intake manifold
     
    Fuel hoses and wiring harness connections to the fuel rail
     
    Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses
     
    Negative battery cable
     

  26.  
  27. Fill the engine with clean oil.
  28.  
  29. Fill and bleed the cooling system.
  30.  
  31. Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
  32.  

 
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