LS400 1990-1997

Camshaft, Bearings & Lifters

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Removal & Installation



Specific to:

Lexus LS400 1993-1994



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Fig. Installing the I6 bearing cap-intake camshaft, right cylinder head - 1993-94 LS400



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Fig. Installing the bearing caps-intake camshaft, right cylinder head - 1993-94 LS400

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the camshaft timing pulleys.
  6.  
  7. Disconnect the accelerator cable, the throttle control cable, if equipped with automatic transmission and the cruise control actuator cable.
  8.  
  9. Remove the high tension cord cover and the right side ignition coil.
  10.  
  11. Remove the water inlet housing mounting bolts and disconnect the water bypass hose from the ISC valve.
  12.  
  13. Remove the water inlet and inlet housing assemblies. Remove the O-ring from the water inlet housing.
  14.  
  15. Remove the EGR pipe.
  16.  
  17. Disconnect the following:
    1. VSV connector
    2.  
    3. Vacuum pipe hose
    4.  
    5. EGR water bypass pipe
    6.  
    7. Fuel pressure VSV
    8.  

  18.  
  19. Disconnect the EGR vacuum hoses and remove the EGR VSV.
  20.  
  21. Disconnect these hoses:
    1. Water bypass pipe hose from the ISC valve.
    2.  
    3. Water bypass joint hose.
    4.  
    5. Vacuum pipe hoses.
    6.  

  22.  
  23. Disconnect the EGR gas temperature sensor, California only. Remove the EGR valve adapter.
  24.  
  25. Disconnect the following:
    1. Fuel pressure regulator vacuum hose.
    2.  
    3. Air intake chamber vacuum hose.
    4.  
    5. Vacuum hose from the EVAP BVSV.
    6.  

  26.  
  27. Remove the mounting bolts, hoses and the vacuum pipe.
  28.  
  29. Remove the ISC valve.
  30.  
  31. Remove the throttle body sensor connectors and the water bypass pipe from the rear water bypass joint.
  32.  
  33. Disconnect the PCV valve hose. Remove the throttle body and gasket.
  34.  
  35. Disconnect the accelerator cable bracket and the brake booster vacuum union and hose.
  36.  
  37. Disconnect the cold start injector connector and the cold start injector tube from the right side delivery pipe, if equipped.
  38.  
  39. Disconnect the check connector from the intake chamber and remove the mounting nuts and bolts.
  40.  
  41. Remove the air intake chamber and the cold start injector, tube and wire assembly, if equipped.
  42.  
  43. Disconnect the engine wire from the intake manifold and from the right side cylinder head. Disconnect the heater hoses.
  44.  
  45. Remove the delivery pipes and the fuel injectors. Remove the mounting bolts and nuts. Lift up the intake manifold.
  46.  
  47. Remove the front and rear water bypass joint.
  48.  
  49. Raise and safely support the vehicle. Remove the front exhaust pipe and the main catalytic converters. Lower the vehicle.
  50.  
  51. Disconnect the right side oxygen sensor. Remove the mounting bolts and nuts and remove the right side exhaust manifold.
  52.  
  53. Remove the oil dipstick and guide. Disconnect the left side oxygen sensor.
  54.  
  55. Remove the mounting bolts and nuts and remove the left side exhaust manifold.
  56.  
  57. Remove the 2 engine hangers and the wire brackets from the right side cylinder head.
  58.  
  59. Remove the bolts, washers and the cylinder head cover. Remove the semi-circular plugs, if necessary.
  60.  
  61. To remove the exhaust camshaft from the right side cylinder head:
    1. Position the service bolt hole of the drive sub-gear to the upright position. Secure the camshaft sub-gear to drive gear with a service bolt.
    2.  
    3. Set the timing mark (single dot) on the camshaft drive gear at approximately 10 degrees. 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.  

  62.  
  63. To remove the intake camshaft from the right side cylinder head:
    1. Set the timing mark (single dot) on the camshaft drive gear at approximately 45 degrees. Turn the camshaft with a wrench on the hexagonal flats.
    2.  
    3. Uniformly loosen (in several passes) and remove the bearing cap bolts in the proper sequence.
    4.  
    5. Remove the bearing caps, oil seal and the intake camshaft.
    6.  

  64.  
  65. To remove the exhaust camshaft of the left side cylinder head:
    1. Position the service bolt hole of the drive sub-gear to the upright position. Secure the camshaft sub-gear to drive gear with a service bolt.
      NOTE
      When removing the camshaft, make sure the torsional spring force of the sub-gear has been eliminated.

    2.  
    3. Set the timing mark (2 dots) on the camshaft drive gear at approximately 15 degrees, 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.  

  66.  
  67. 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 degrees, 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.  

  68.  

To install:

  1. Remove any old packing and apply new seal packing to the bearing caps.

    Click image to see an enlarged view

    Fig. Installing the bearing cap bolts-intake camshaft, right cylinder head - 1993-94



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    Fig. Camshaft torquing sequence-intake camshaft, right cylinder head - 1993-94



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    Fig. Installing the E1 bearing cap-exhaust camshaft, right cylinder head - 1993-94



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    Fig. Installing the bearing caps-exhaust camshaft, right cylinder head - 1993-94



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    Fig. Installing the bearing cap bolts-exhaust camshaft, right cylinder head - 1993-94



    Click image to see an enlarged view

    Fig. Camshaft bearing cap torquing sequence-exhaust camshaft, right cylinder head - 1993-94



    Click image to see an enlarged view

    Fig. Installing the I1 bearing cap-intake camshaft, left cylinder head - 1993-94



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    Fig. Installing the bearing caps-intake camshaft, left cylinder - 1993-94



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    Fig. Installing the bearing cap bolts-intake manifold, left cylinder head - 1993-94



    Click image to see an enlarged view

    Fig. Camshaft bearing cap torquing sequence-intake camshaft, left cylinder head - 1993-94



    Click image to see an enlarged view

    Fig. Installing the E1 bearing cap-exhaust camshaft, left cylinder head - 1993-94



    Click image to see an enlarged view

    Fig. Exhaust bearing caps-exhaust camshaft, left cylinder head - 1993-94



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    Fig. Installing the bearing cap bolts-exhaust camshaft, left cylinder head - 1993-94



    Click image to see an enlarged view

    Fig. Camshaft bearing cap torquing sequence-exhaust camshaft, left cylinder head - 1993-94

  2.  
  3. Install the 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.
  4.  
  5. Apply a light coat of oil on the threads of the cap bolts. Install the bearing cap bolts with new washers and tighten to 12 ft. lbs. (16 Nm).
  6.  
  7. 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 degree 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).
    12.  

  8.  
  9. To install the right side cylinder head exhaust camshaft:
    1. Set the timing mark (single dot) on the camshaft drive gear at a 10 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 (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.  

  10.  
  11. 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 degree 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.  

  12.  
  13. Install the left side cylinder head exhaust camshaft:
    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 ion 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.  

  14.  
  15. Install the camshaft oil seals with the proper tool. Install the semi-circular plugs with the proper seal packing.
  16.  
  17. Install the cylinder head covers with the proper seal packing and gasket. Tighten the mounting bolts to 52 inch lbs. (6 Nm).
  18.  
  19. Install the engine wire bracket and hangers. Tighten the hanger bolts to 27 ft. lbs. (37 Nm).
  20.  
  21. Install the right side exhaust manifold with a new gasket and tighten the mounting bolts to 29 ft. lbs. (40 Nm). Connect the right side oxygen sensor connector.
  22.  
  23. Install the right side exhaust manifold with a new gasket and tighten the mounting bolts to 29 ft. lbs. (40 Nm). Connect the right side oxygen sensor connector.
  24.  
  25. Install the left side exhaust manifold with a new gasket and tighten the mounting bolts to 29 ft. lbs. (40 Nm). Connect the left side oxygen sensor connector.
  26.  
  27. Install the remaining components. Tighten the intake manifold nuts and bolts to 13 ft. lbs. (18 Nm).
  28.  
  29. Tighten the timing belt rear plates to 69 inch lbs. (7.7 Nm).
  30.  
  31. Connect and adjust the accelerator cable, the automatic transmission throttle cable and the cruise control actuator cable. Install the camshaft timing pulley.
  32.  
  33. Fill the cooling system.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Start the engine and check for leaks.
  38.  
  39. Recheck all the fluid levels and check the ignition timing.
  40.  

Specific to:

Lexus LS400 1995-1997

  1. Disconnect the negative battery cable. Wait at least 90 seconds before performing any other work. Disconnect the positive battery cable and remove the battery.
  2.  
  3. Remove the air cleaner inlet.
  4.  
  5. Remove the V bank cover by removing the bolt and two cap nuts.
  6.  
  7. Relieve the fuel pressure from the fuel lines.
    CAUTION
    Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  8.  
  9. Remove the air cleaner and intake air connector assembly.
  10.  
  11. Remove the 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.
  12.  
  13. Remove the radiator.
  14.  
  15. Remove the right hand No. 3 timing belt cover.
  16.  
  17. Remove the left hand No. 3 timing belt cover, for 1995 California vehicles and all 1996-97 vehicles, disconnect the 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. Remove the four bolts to the left hand timing belt cover. Disconnect the cord grommet from the timing belt cover and remove the timing belt cover.
  18.  
  19. Remove the drive belt idler pulley by removing the pulley bolt and cover plate.
  20.  
  21. Remove the right hand and left No. 2 timing belt covers.
  22.  
  23. Remove the distributor housings.
  24.  
  25. Remove the No. 1 ignition coil.
  26.  
  27. Disconnect the A/C compressor from the engine. Do not disconnect the A/C pressure lines.
  28.  
  29. Remove the fan bracket by removing the two bolts and two nuts.
  30.  
  31. Disconnect and remove the alternator from the engine.
  32.  
  33. Remove the drive belt tensioner.
  34.  
  35. Set the engine to TDC on cylinder No. 1. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 full revolution (360 degrees).
  36.  
  37. 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.

  38.  
  39. If the timing belt is to be reused, turn the crank pulley slowly; check that the three 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.
  40.  
  41. Remove the timing belt tensioner. Alternately loosen the two bolts; remove the bolts, the tensioner and the dust protector.
  42.  
  43. Using the proper tool, 09278-54012, or equivalent, loosen the tension between the left side and right side timing pulleys by slightly turning the left side camshaft clockwise.
  44.  
  45. Disconnect the timing belt from the camshaft timing pulleys.
  46.  
  47. Using the proper tool (SST 09960-10010 or equivalent), remove the bolt and the camshaft timing pulleys.
  48.  
  49. Remove the No. 2 ignition coil.
  50.  
  51. Remove the rear timing belt plates by removing the two bolts to each plate.
  52.  
  53. Remove the throttle body.
  54.  
  55. Remove the spark plug wires, wire clamps and the wire cover assembly from the right cylinder head.
  56.  
  57. Remove the right cylinder head cover by removing the eight bolts and eight washers.
  58.  
  59. Remove the transmission oil dipstick.
  60.  
  61. Disconnect the EVAP hose (from the charcoal canister) from the vacuum switching valve.
  62.  
  63. Disconnect the engine wire clamp from the wire bracket on the delivery pipe.
  64.  
  65. Disconnect the spark plug wires and clamps from the left hand cylinder head cover.
  66.  
  67. Remove the left cylinder head cover by removing the eight bolts and eight seal washers.
  68.  
  69. Remove the semi-circular plugs, if necessary.
    NOTE
    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.

  70.  
  71. To remove the exhaust camshaft from the right side cylinder head:
    1. Position the service bolt hole of the drive sub-gear to the upright position. Secure the camshaft sub-gear to drive gear with a service bolt.
    2.  
    3. Set the timing mark (single dot) on the camshaft drive gear at approximately 10 degrees. 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.

      Click image to see an enlarged view

      Fig. Right side exhaust camshaft bracket bolts removal sequence - 1995-97 LS400

    10.  

  72.  
  73. To remove the intake camshaft from the right side cylinder head:
    1. Set the timing mark (single dot) on the camshaft drive gear at approximately 45 degrees. Turn the camshaft with a wrench on the hexagonal flats.
    2.  
    3. Uniformly loosen (in several passes) and remove the bearing cap bolts in the proper sequence.
    4.  
    5. Remove the bearing caps, oil seal and the intake camshaft.

      Click image to see an enlarged view

      Fig. Right side intake camshaft bracket bolts removal sequence - 1995-97 LS400

    6.  

  74.  
  75. To remove the exhaust camshaft of the left side cylinder head:
    1. Position the service bolt hole of the drive sub-gear to the upright position. Secure the camshaft sub-gear to drive gear with a service bolt.
      NOTE
      When removing the camshaft, make sure the torsional spring force of the sub-gear has been eliminated.

    2.  
    3. Set the timing mark (2 dots) on the camshaft drive gear at approximately 15 degrees, 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.

      Click image to see an enlarged view

      Fig. Left side exhaust camshaft bracket bolts removal sequence - 1995-97 LS400

    10.  

  76.  
  77. 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 degrees, 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.  

  78.  
  79. 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.
  80.  

To install:

  1. Install the valve lash adjusters into their original positions and install the shims. Check valve clearance and replace the shims as necessary.
  2.  
  3. When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage.
  4.  
  5. Remove any old packing and apply new seal packing to the bearing caps.
  6.  
  7. Install the 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.
  8.  
  9. Apply a light coat of oil on the threads of the cap bolts. Install the bearing cap bolts with new washers and tighten to 12 ft. lbs. (16 Nm).
  10.  
  11. 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 degree 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. Right side intake camshaft bracket bolt tightening sequence - 1995-97 LS400



      Click image to see an enlarged view

      Fig. Left side intake camshaft bracket bolt tightening sequence - LS400



      Click image to see an enlarged view

      Fig. Left side exhaust camshaft bracket bolt tightening sequence - LS400

    12.  

  12.  
  13. To install the right side cylinder head exhaust camshaft:
    1. Set the timing mark (single dot) on the camshaft drive gear at a 10 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 (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.

      Click image to see an enlarged view

      Fig. Right side exhaust camshaft bracket bolt tightening sequence - 1995-97 LS400

    14.  

  14.  
  15. 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 degree 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.  

  16.  
  17. 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.  
    13. Bring the service bolt installed upward by turning the camshaft with the proper tool. Remove the service bolt.
    14.  

  18.  
  19. Install the camshaft oil seals with the proper tool (SST 09223-46011). Make sure to apply MP grease to the new oil seal lip.
  20.  
  21. Install the semi-circular plugs to the cylinder heads.
  22.  
  23. Clean the cylinder head covers. Apply new sealant in the correct locations and install the gaskets.
  24.  
  25. Install the left cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
  26.  
  27. Connect the spark plug wires and clamps to the left cylinder head cover.
  28.  
  29. Connect the engine wire clamp to the wire bracket on the delivery pipe.
  30.  
  31. Connect the EVAP hose to the VSV.
  32.  
  33. Install the transmission oil dipstick.
  34.  
  35. Install the right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).
  36.  
  37. Connect the spark plug wires and clamps to the right cylinder head cover.
  38.  
  39. Install the throttle body to the air intake chamber. Install the two bolts and two nuts and torque to 13 ft. lbs. (18 Nm).
  40.  
  41. Install the timing belt rear plates by installing the bolts. Torque the bolts to 66 inch lbs. (8 Nm).
  42.  
  43. Install the No. 2 ignition coil.
  44.  
  45. 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).
  46.  
  47. 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).
  48.  
  49. Turn the crankshaft pulley and align its groove with the 0 timing mark on the timing belt cover.
  50.  
  51. Turn each camshaft timing pulley and align the timing marks of the pulley with the timing belt rear plate.
  52.  
  53. Install the timing belt to the left side camshaft timing pulley:
    1. 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.
    2.  
    3. Align the timing marks of the left side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the left side camshaft pulley.
    6.  

  54.  
  55. Install the timing belt to the right side camshaft timing pulley:
    1. 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.
    2.  
    3. Align the timing marks of the right side camshaft pulley and the timing belt rear plate.
    4.  
    5. Check that the timing belt has tension between crankshaft timing pulley and the right side camshaft pulley.
    6.  

  56.  
  57. 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 220-2205 lbs. of pressure.
    2.  
    3. Align the holes of the pushrod and housing, pass a 1.27mm Allen wrench 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.  

  58.  
  59. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner.
  60.  
  61. Turn the crankshaft pulley two 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.
  62.  
  63. Install the remaining components. Install the V bank cover.
  64.  
  65. Fill the radiator with engine coolant.
  66.  
  67. Install the battery and battery tray. Connect the battery cables, positive cable first.
  68.  
  69. Start the engine and check for leaks.
  70.  
  71. Recheck the engine coolant level.
  72.  
  73. Install the air cleaner inlet.
  74.  
  75. Install the battery clamp cover.
  76.  
  77. Install the engine undercover.
  78.  
  79. Install the oil pan protector.
  80.  
  81. Lower the vehicle.
  82.  

 
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