Land Rover 2000-05

Camshaft, Bearings & Lifters

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Removal & Installation



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

    Engine from the vehicle
     
    Intake manifold and gasket
     
    Both rocker arm shaft assemblies
     

  4.  


NOTE
Identify each rocker shaft assembly to ensure installation on original cylinder bank.



Pushrods and place them in order
 
Valve lifters and place them in order
 
Front cover and timing chain
 
Camshaft thrust plate
 
Camshaft
 


NOTE
The camshaft installed in the 4.0L engines is color-coded orange, while the camshaft in the 4.6L engines is color-coded red.

To install:



Click image to see an enlarged view

Fig. Exploded view of the camshaft (7) and thrust plate (6) mounting-Discover Series II (2001-04) and Range Rover (2001-02)

  1. Lubricate the camshaft journals with engine oil.
  2.  
  3. Install or connect the following:

    Camshaft into cylinder block. Tighten the thrust plate mounting bolts to 18 ft. lbs. (25 Nm).
     
    Timing chain and front cover
     

  4.  
  5. Soak the lifters in engine oil. Before installing each lifter, pump the inner sleeve of the lifter several times using a pushrod to prime the lifter; this will reduce lifter noise when the engine is first started.
  6.  
  7. Lubricate the lifter bores with engine oil, then install the lifters.
  8.  


NOTE
Some lifter noise may still be heard on initial start-up. If necessary, run the engine at 2500 rpm for a few minutes until the noise clears.

  1. Install or connect the following:

    Pushrods
     
    Rocker arm shaft assemblies
     
    Intake manifold
     
    Engine
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove intake manifold.
  4.  
  5. Remove rocker shaft assemblies as follows:
    1. Progressively loosen and remove 8 bolts securing rocker shaft assemblies.
    2.  
    3. Mark each rocker shaft in relation to original position and cylinder head.
    4.  
    5. Remove rocker shaft assemblies.
    6.  

  6.  
  7. Remove push rods and store in their order as removed.
  8.  
  9. Remove tappets. Keep tappets in order and orientation as they are removed.
  10.  
  11. Remove timing chain and gears.
  12.  
  13. Before removing the camshaft, check camshaft end play as follows:
    1. Temporarily fit camshaft gear and lightly tighten the retaining bolt.
    2.  
    3. Attach a dial indicator to front of cylinder block with tip of dial indicator contacting surface of camshaft gear.
    4.  
    5. Push camshaft rearward and zero the dial indicator.
    6.  
    7. Using the camshaft gear, pull the camshaft forward and note the dial indicator reading.
    8.  
    9. End play should be within 0.003-0.010 inch (0.075-0.25mm).
    10.  
    11. If end play is not within specified range, install a new thrust plate. If end play is still not within range, a new camshaft and/or gear must be installed.
    12.  
    13. Remove dial indicator, camshaft gear bolt and gear.
    14.  

  14.  
  15. Remove the 2 bolts holding the camshaft thrust plate, and remove the thrust plate.
  16.  
  17. Carefully remove the camshaft, avoiding damage to camshaft bearings.
  18.  

To install:

  1. Clean camshaft bearings in cylinder block.
  2.  
  3. Clean the camshaft.
  4.  
  5. Wipe the camshaft bearing faces and lobes.
  6.  
  7. Clean the thrust plate and mating face.
  8.  
  9. Lubricate the camshaft bearings with clean engine oil.
  10.  
  11. Position the thrust plate. Install and tighten the bolts to 17 ft. lbs. (22 Nm).
  12.  
  13. Install the timing chain and gears.
  14.  
  15. Immerse the tappets in engine oil before installation. Pump the inner sleeve of the tappet several times, using a push rod to prime the tappets. Clean the tappet bores.
  16.  
  17. Lubricate the tappets and tappet bores with clean engine oil.
  18.  
  19. Install the tappets in their original positions.
  20.  
  21. Clean the pushrods. Lubricate the tappet end of the push rods with clean engine oil.
  22.  
  23. Install the push rods in their original locations.
  24.  
  25. Clean the bases of the rocker pillars and mating faces.
  26.  
  27. Clean the contact surfaces of the rockets and valves, then lubricate the contact surfaces with clean engine oil.
  28.  
  29. Fit the rocker shafts and engage the push rods. Ensure the rocker shafts are installed in the correct locations as removed.
  30.  
  31. Install and progressively tighten the rocker shaft bolts to 30 ft. lbs. (40 Nm).
  32.  
  33. Install a new intake manifold gasket.
  34.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the cylinder heads. Refer to the procedure in this section.
  4.  
  5. Remove the exhaust camshaft drive chain tensioner.
  6.  
  7. Remove the Variable Camshaft Control (VCC) oil distribution housing. Remove and discard sealing washer from the long bolt.
  8.  
  9. Remove 3 VCC oil non-return rings from the intake camshaft.
  10.  
  11. Fit an M10 bolt into the VCC non-return valve and by hand, remove the valve. Discard the o-ring.
  12.  
  13. Check camshaft end play. End play should be 0.08-0.014 inch (0.20-0.36 mm).
  14.  
  15. Using a wrench on the intake camshaft hexagon, rotate the camshaft until the lobes of cylinder no. 8 face upward.
  16.  
  17. Using a wrench on the exhaust camshaft hexagon, rotate the camshaft until the lobes of cylinder no. 6 face upward.
  18.  
  19. Identify the camshaft bearing caps for installation reference as shown.
  20.  
  21. Evenly and progressively loosen and remove 10 nuts attaching the intake camshaft bearing caps, and remove the caps.
  22.  
  23. Remove the intake camshaft.
  24.  
  25. Evenly and progressively loosen and remove 10 nuts attaching the exhaust camshaft bearing caps, and remove the caps.
  26.  
  27. Remove the exhaust camshaft.
  28.  
  29. Remove tappets. Keep tappets in order and orientation as they are removed.
  30.  


    Click image to see an enlarged view

    Fig. Identifying camshaft bearing caps-Range Rover (2003-04)


To install:

  1. Lubricate the tappets and bores. Install the tappets in their original positions.
  2.  
  3. Clean the camshaft.
  4.  
  5. Wipe the camshaft bearing faces and caps.
  6.  
  7. Lubricate the camshaft and bearings.
  8.  
  9. Install the exhaust camshaft with the lobes of no. 6 cylinder facing upward.
  10.  
  11. Fit the bearing caps marked A in the correct order.
  12.  
  13. Evenly and progressively tighten the 10 nuts attaching the exhaust camshaft bearing caps to 10 ft. lbs. (14 Nm).
  14.  
  15. Install the intake camshaft with the lobes of no. 8 cylinder facing upward.
  16.  
  17. Fit the bearing caps marked E in the correct order.
  18.  
  19. Evenly and progressively tighten the 10 nuts attaching the intake camshaft bearing caps to 10 ft. lbs. (14 Nm).
  20.  
  21. Clean the VCC non-return valve, and using a new o-ring, install the valve.
  22.  
  23. Lubricate the VCC rings and carefully fit the rings in the intake camshaft grooves with the ring gaps facing upward.
  24.  
  25. Clean the VCC oil distribution housing and cylinder head mating surfaces.
  26.  
  27. Using a new gasket, install the VCC housing.
  28.  
  29. Install a new sealing washer to the long bolt, then install VCC housing bolts and tighten to 7 ft. lbs. (10 Nm).
  30.  
  31. Lubricate the exhaust camshaft drive chain tensioner.
  32.  
  33. Using a new o-ring, install the chain tensioner and tighten the bolts to 7 ft. lbs. (10 Nm).
  34.  
  35. Install the cylinder heads.
  36.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Identify each rocker shaft assembly to ensure installation on original cylinder bank.


    NOTE
    The camshaft installed in the 4.0L engines is color-coded orange, while the camshaft in the 4.6L engines is color-coded red.



    Engine from the vehicle
     
    Intake manifold and gasket
     
    Both rocker arm shaft assemblies
     



    Pushrods and place them in order
     
    Valve lifters and place them in order
     
    Front cover and timing chain
     
    Camshaft thrust plate
     
    Camshaft
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the camshaft (7) and thrust plate (6) mounting

  1. Lubricate the camshaft journals with engine oil.
  2.  
  3. Install or connect the following:

    Camshaft into cylinder block. Tighten the thrust plate mounting bolts to 18 ft. lbs. (25 Nm).
     
    Timing chain and front cover
     

  4.  
  5. Soak the lifters in engine oil. Before installing each lifter, pump the inner sleeve of the lifter several times using a pushrod to prime the lifter; this will reduce lifter noise when the engine is first started.
  6.  
  7. Lubricate the lifter bores with engine oil, then install the lifters.
    NOTE
    Some lifter noise may still be heard on initial start-up. If necessary, run the engine at 2500 rpm for a few minutes until the noise clears.

  8.  
  9. Install or connect the following:

    Pushrods
     
    Rocker arm shaft assemblies
     
    Intake manifold
     
    Engine
     

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Identify each rocker shaft assembly to ensure installation on original cylinder bank.


    NOTE
    The camshaft installed in the 4.0L engines is color-coded orange, while the camshaft in the 4.6L engines is color-coded red.



    Engine from the vehicle
     
    Intake manifold and gasket
     
    Both rocker arm shaft assemblies
     



    Pushrods and place them in order
     
    Valve lifters and place them in order
     
    Front cover and timing chain
     
    Camshaft thrust plate
     
    Camshaft
     

  4.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the camshaft (7) and thrust plate (6) mounting-Discover Series II (2000-04) and Range Rover (2000-02)

  1. Lubricate the camshaft journals with engine oil.
  2.  
  3. Install or connect the following:

    Camshaft into cylinder block. Tighten the thrust plate mounting bolts to 18 ft. lbs. (25 Nm).
     
    Timing chain and front cover
     

  4.  
  5. Soak the lifters in engine oil. Before installing each lifter, pump the inner sleeve of the lifter several times using a pushrod to prime the lifter; this will reduce lifter noise when the engine is first started.
  6.  
  7. Lubricate the lifter bores with engine oil, then install the lifters.
    NOTE
    Some lifter noise may still be heard on initial start-up. If necessary, run the engine at 2500 rpm for a few minutes until the noise clears.

  8.  
  9. Install or connect the following:

    Pushrods
     
    Rocker arm shaft assemblies
     
    Intake manifold
     
    Engine
     

  10.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove intake manifold.
  4.  
  5. Remove rocker shaft assemblies as follows:
    1. Progressively loosen and remove 8 bolts securing rocker shaft assemblies.
    2.  
    3. Mark each rocker shaft in relation to original position and cylinder head.
    4.  
    5. Remove rocker shaft assemblies.
    6.  

  6.  
  7. Remove push rods and store in their order as removed.
  8.  
  9. Remove tappets. Keep tappets in order and orientation as they are removed.
  10.  
  11. Remove timing chain and gears.
  12.  
  13. Before removing the camshaft, check camshaft end play as follows:
    1. Temporarily fit camshaft gear and lightly tighten the retaining bolt.
    2.  
    3. Attach a dial indicator to front of cylinder block with tip of dial indicator contacting surface of camshaft gear.
    4.  
    5. Push camshaft rearward and zero the dial indicator.
    6.  
    7. Using the camshaft gear, pull the camshaft forward and note the dial indicator reading.
    8.  
    9. End play should be within 0.003-0.010 inch (0.075-0.25mm).
    10.  
    11. If end play is not within specified range, install a new thrust plate. If end play is still not within range, a new camshaft and/or gear must be installed.
    12.  
    13. Remove dial indicator, camshaft gear bolt and gear.
    14.  

  14.  
  15. Remove the 2 bolts holding the camshaft thrust plate, and remove the thrust plate.
  16.  
  17. Carefully remove the camshaft, avoiding damage to camshaft bearings.
  18.  

To install:

  1. Clean camshaft bearings in cylinder block.
  2.  
  3. Clean the camshaft.
  4.  
  5. Wipe the camshaft bearing faces and lobes.
  6.  
  7. Clean the thrust plate and mating face.
  8.  
  9. Lubricate the camshaft bearings with clean engine oil.
  10.  
  11. Position the thrust plate. Install and tighten the bolts to 17 ft. lbs. (22 Nm).
  12.  
  13. Install the timing chain and gears.
  14.  
  15. Immerse the tappets in engine oil before installation. Pump the inner sleeve of the tappet several times, using a push rod to prime the tappets. Clean the tappet bores.
  16.  
  17. Lubricate the tappets and tappet bores with clean engine oil.
  18.  
  19. Install the tappets in their original positions.
  20.  
  21. Clean the pushrods. Lubricate the tappet end of the push rods with clean engine oil.
  22.  
  23. Install the push rods in their original locations.
  24.  
  25. Clean the bases of the rocker pillars and mating faces.
  26.  
  27. Clean the contact surfaces of the rockets and valves, then lubricate the contact surfaces with clean engine oil.
  28.  
  29. Fit the rocker shafts and engage the push rods. Ensure the rocker shafts are installed in the correct locations as removed.
  30.  
  31. Install and progressively tighten the rocker shaft bolts to 30 ft. lbs. (40 Nm).
  32.  
  33. Install a new intake manifold gasket.
  34.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the cylinder heads. Refer to the procedure in this section.
  4.  
  5. Remove the exhaust camshaft drive chain tensioner.
  6.  
  7. Remove the Variable Camshaft Control (VCC) oil distribution housing. Remove and discard sealing washer from the long bolt.
  8.  
  9. Remove 3 VCC oil non-return rings from the intake camshaft.
  10.  
  11. Fit an M10 bolt into the VCC non-return valve and by hand, remove the valve. Discard the o-ring.
  12.  
  13. Check camshaft end play. End play should be 0.08-0.014 inch (0.20-0.36 mm).
  14.  
  15. Using a wrench on the intake camshaft hexagon, rotate the camshaft until the lobes of cylinder no. 8 face upward.
  16.  
  17. Using a wrench on the exhaust camshaft hexagon, rotate the camshaft until the lobes of cylinder no. 6 face upward.
  18.  
  19. Identify the camshaft bearing caps for installation reference as shown.

    Click image to see an enlarged view

    Fig. Identifying camshaft bearing caps-Range Rover (2003-04)

  20.  
  21. Evenly and progressively loosen and remove 10 nuts attaching the intake camshaft bearing caps, and remove the caps.
  22.  
  23. Remove the intake camshaft.
  24.  
  25. Evenly and progressively loosen and remove 10 nuts attaching the exhaust camshaft bearing caps, and remove the caps.
  26.  
  27. Remove the exhaust camshaft.
  28.  
  29. Remove tappets. Keep tappets in order and orientation as they are removed.
  30.  

To install:

  1. Lubricate the tappets and bores. Install the tappets in their original positions.
  2.  
  3. Clean the camshaft.
  4.  
  5. Wipe the camshaft bearing faces and caps.
  6.  
  7. Lubricate the camshaft and bearings.
  8.  
  9. Install the exhaust camshaft with the lobes of no. 6 cylinder facing upward.
  10.  
  11. Fit the bearing caps marked A in the correct order.
  12.  
  13. Evenly and progressively tighten the 10 nuts attaching the exhaust camshaft bearing caps to 10 ft. lbs. (14 Nm).
  14.  
  15. Install the intake camshaft with the lobes of no. 8 cylinder facing upward.
  16.  
  17. Fit the bearing caps marked E in the correct order.
  18.  
  19. Evenly and progressively tighten the 10 nuts attaching the intake camshaft bearing caps to 10 ft. lbs. (14 Nm).
  20.  
  21. Clean the VCC non-return valve, and using a new o-ring, install the valve.
  22.  
  23. Lubricate the VCC rings and carefully fit the rings in the intake camshaft grooves with the ring gaps facing upward.
  24.  
  25. Clean the VCC oil distribution housing and cylinder head mating surfaces.
  26.  
  27. Using a new gasket, install the VCC housing.
  28.  
  29. Install a new sealing washer to the long bolt, then install VCC housing bolts and tighten to 7 ft. lbs. (10 Nm).
  30.  
  31. Lubricate the exhaust camshaft drive chain tensioner.
  32.  
  33. Using a new o-ring, install the chain tensioner and tighten the bolts to 7 ft. lbs. (10 Nm).
  34.  
  35. Install the cylinder heads.
  36.  

Left Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Remove camshaft timing belt.
  6.  
  7. Remove the left SIDE camshaft rear timing belt.
  8.  
  9. For 2000-02 models, remove the left SIDE camshaft cover gasket.
  10.  
  11. Remove the front camshaft drive belt cover backplate from the cylinder head.
  12.  
  13. Remove the left SIDE rear camshaft drive belt cover backplate from the rear of the cylinder head.
  14.  
  15. Using the sequence shown, progressively loosen the 22 bolts securing the camshaft carrier to the cylinder head. Loosen bolts until valve spring pressure is released, then remove the bolts.
  16.  
  17. Release the camshaft carrier from the dowels and remove the carrier.
  18.  
  19. Remove the camshaft and remove and discard the oil seals.
  20.  
  21. Disconnect CMP sensor multiplug and release male multiplug from mounting bracket.
  22.  
  23. Using a stick magnet, remove the 12 hydraulic tappets from the cylinder head, keeping tappets in order as removed for installation in original positions.
  24.  


CAUTION
Maintain absolute cleanliness when handling hydraulic tappets. Failure to do so can result in engine damage.



Click image to see an enlarged view

Fig. Camshaft carrier bolt loosening sequence-Freelander (2001-04)

  1. Clean camshafts and bearing running surfaces in camshaft carrier and cylinder head.
  2.  
  3. Inspect camshafts and replace camshafts if scored, pitted or excessively worn.
  4.  


NOTE
Camshafts are color-coded blue for exhaust and orange for intake.

To install:

  1. Thoroughly clean and lubricate hydraulic tappets with clean engine oil. Fit hydraulic tappets to original bores in cylinder head.
  2.  
  3. Ensure that mating faces of camshaft carrier and cylinder head are clean and dry.
  4.  
  5. Lubricate camshafts and bearing journals with clean engine oil.
  6.  
  7. Position camshafts in cylinder head with rear timing gear drive slots in each camshaft facing towards the center as shown.
  8.  
  9. Apply continuous thin beads of sealant STC 4600 to paths on camshaft carrier as shown. Spread sealant to an even film using a roller.
  10.  


    Click image to see an enlarged view

    Fig. Camshaft installed positions-Freelander (2001-04)



    Click image to see an enlarged view

    Fig. Camshaft carrier bolt torque sequence-Freelander (2001-04)



CAUTION
To avoid contamination, assembly should be completed immediately after application of sealant.

  1. Position camshaft carrier, fit and progressively tighten bolts in the sequence shown to 7.5 ft. lbs. (10 Nm).
  2.  
  3. Noting that the front camshaft oil seals are black in color and the rear oil seals are red, fit new camshaft oil seals using LRT-12-203 and LRT -12-148A
  4.  


CAUTION
Oil seal is waxed on outer diameter and must not be lubricated before fitting.



Click image to see an enlarged view

Fig. Sealant application pattern on camshaft carrier-Freelander (2001-04)



Click image to see an enlarged view

Fig. Camshaft cover bolt torque sequence-Freelander (2001-04)

  1. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
  2.  
  3. Position camshaft timing belt rear cover backplates to cylinder head, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  4.  
  5. On 2000-02 models, install a new left camshaft cover gasket.
  6.  
  7. Install the front and rear camshaft timing belts.
  8.  
  9. Check and refill all fluids, as needed.
  10.  
  11. Connect battery ground lead.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Remove camshaft timing belt.
  6.  
  7. Remove the left SIDE camshaft rear timing belt.
  8.  
  9. For 2000-02 models, remove the left SIDE camshaft cover gasket.
  10.  
  11. Remove the front camshaft drive belt cover backplate from the cylinder head.
  12.  
  13. Remove the left SIDE rear camshaft drive belt cover backplate from the rear of the cylinder head.
  14.  
  15. Using the sequence shown, progressively loosen the 22 bolts securing the camshaft carrier to the cylinder head. Loosen bolts until valve spring pressure is released, then remove the bolts.
  16.  
  17. Release the camshaft carrier from the dowels and remove the carrier.
  18.  
  19. Remove the camshaft and remove and discard the oil seals.
  20.  
  21. Disconnect CMP sensor multiplug and release male multiplug from mounting bracket.
  22.  
  23. Using a stick magnet, remove the 12 hydraulic tappets from the cylinder head, keeping tappets in order as removed for installation in original positions.
    CAUTION
    Maintain absolute cleanliness when handling hydraulic tappets. Failure to do so can result in engine damage.



    Click image to see an enlarged view

    Fig. Camshaft carrier bolt loosening sequence-Freelander (2000-04)

  24.  
  25. Clean camshafts and bearing running surfaces in camshaft carrier and cylinder head.
  26.  
  27. Inspect camshafts and replace camshafts if scored, pitted or excessively worn.
    NOTE
    Camshafts are color-coded blue for exhaust and orange for intake.

  28.  

To install:

  1. Thoroughly clean and lubricate hydraulic tappets with clean engine oil. Fit hydraulic tappets to original bores in cylinder head.
  2.  
  3. Ensure that mating faces of camshaft carrier and cylinder head are clean and dry.
  4.  
  5. Lubricate camshafts and bearing journals with clean engine oil.
  6.  
  7. Position camshafts in cylinder head with rear timing gear drive slots in each camshaft facing towards the center as shown.

    Click image to see an enlarged view

    Fig. Camshaft installed positions-Freelander (2000-04)



    Click image to see an enlarged view

    Fig. Camshaft carrier bolt torque sequence-Freelander (2000-04)

  8.  
  9. Apply continuous thin beads of sealant STC 4600 to paths on camshaft carrier as shown. Spread sealant to an even film using a roller.
    CAUTION
    To avoid contamination, assembly should be completed immediately after application of sealant.

  10.  
  11. Position camshaft carrier, fit and progressively tighten bolts in the sequence shown to 7.5 ft. lbs. (10 Nm).
  12.  
  13. Noting that the front camshaft oil seals are black in color and the rear oil seals are red, fit new camshaft oil seals using LRT-12-203 and LRT 12-148A
    CAUTION
    Oil seal is waxed on outer diameter and must not be lubricated before fitting.



    Click image to see an enlarged view

    Fig. Sealant application pattern on camshaft carrier-Freelander (2000-04)



    Click image to see an enlarged view

    Fig. Camshaft cover bolt torque sequence-Freelander (2000-04)

  14.  
  15. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
  16.  
  17. Position camshaft timing belt rear cover backplates to cylinder head, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  18.  
  19. On 2000-02 models, install a new left camshaft cover gasket.
  20.  
  21. Install the front and rear camshaft timing belts.
  22.  
  23. Check and refill all fluids, as needed.
  24.  
  25. Connect the negative battery cable.
  26.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Remove right front and rear camshaft timing belts.
  6.  
  7. Remove the right camshaft cover gasket.
  8.  
  9. Remove 4 bolts securing right front timing belt cover backplate to cylinder head and remove backplate.
  10.  
  11. Remove 2 bolts securing right rear timing belt cover backplate and remove backplate.
  12.  
  13. Using sequence shown, progressively loosen 22 bolts securing camshaft carrier to cylinder head until valve spring pressure is released and remove bolts.
  14.  
  15. Release camshaft carrier from dowels and remove carrier.
  16.  
  17. Remove both camshafts and discard oil seals.
  18.  
  19. Using a stick magnet, remove 12 hydraulic tappets from cylinder head.
  20.  


CAUTION
Store hydraulic tappets in their fitted order and store upright. Maintain absolute cleanliness when handling hydraulic tappets. Failure to observe these precautions can result in engine failure.

To install:

  1. Clean camshafts and bearing running surfaces in camshaft carrier and cylinder head.
  2.  
  3. Inspect camshafts and replace camshafts if scored, pitted or excessively worn.
  4.  
  5. Use a lint-free cloth and solvent, clean sealing surfaces on cylinder head and camshaft carrier.
  6.  


NOTE
Camshafts are color-coded blue for exhaust and orange for intake.

  1. Thoroughly clean and lubricate hydraulic tappets with clean engine oil. Install tappets to original bores is cylinder head.
  2.  
  3. Ensure mating faces of camshaft carrier and cylinder head are clean and dry.
  4.  
  5. Lubricate camshafts and bearing journals with clean engine oil.
  6.  
  7. Position camshafts in cylinder head with rear timing gear drive slots in each camshaft facing towards the center as shown.
  8.  
  9. Apply continuous thin beads of sealant STC 4600 to paths on camshaft carrier as shown. Spread sealant to an even film using a roller.
  10.  


CAUTION
To avoid contamination, assembly should be completed immediately after application of sealant.

  1. Position camshaft carrier, fit and progressively tighten bolts in the sequence shown to 7.5 ft. lbs. (10 Nm).
  2.  
  3. Noting that the front camshaft oil seals are black in color and the rear oil seals are red, fit new camshaft oil seals using LRT-12-203 and LRT -12-148A
  4.  


CAUTION
Oil seal is waxed on outer diameter and must not be lubricated before fitting.

  1. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
  2.  
  3. Position camshaft timing belt rear cover backplates to cylinder head, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  4.  
  5. Clean mating surfaces of camshaft cover and carrier.
  6.  
  7. Clean inside of camshaft cover. If necessary, wash oil separator elements in solvent and blow dry.
  8.  
  9. Position new gasket to camshaft carrier with arrows on gasket pointing towards inlet manifold.
  10.  
  11. Fit front and rear camshaft timing belts.
  12.  
  13. Check and refill fluids as necessary.
  14.  
  15. Connect battery ground lead.
  16.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery ground lead.
  4.  
  5. Remove right front and rear camshaft timing belts.
  6.  
  7. Remove the right camshaft cover gasket.
  8.  
  9. Remove 4 bolts securing right front timing belt cover backplate to cylinder head and remove backplate.
  10.  
  11. Remove 2 bolts securing right rear timing belt cover backplate and remove backplate.
  12.  
  13. Using sequence shown, progressively loosen 22 bolts securing camshaft carrier to cylinder head until valve spring pressure is released and remove bolts.
  14.  
  15. Release camshaft carrier from dowels and remove carrier.
  16.  
  17. Remove both camshafts and discard oil seals.
  18.  
  19. Using a stick magnet, remove 12 hydraulic tappets from cylinder head.
    CAUTION
    Store hydraulic tappets in their fitted order and store upright. Maintain absolute cleanliness when handling hydraulic tappets. Failure to observe these precautions can result in engine failure.

  20.  

To install:

  1. Clean camshafts and bearing running surfaces in camshaft carrier and cylinder head.
  2.  
  3. Inspect camshafts and replace camshafts if scored, pitted or excessively worn.
  4.  
  5. Use a lint-free cloth and solvent, clean sealing surfaces on cylinder head and camshaft carrier.
    NOTE
    Camshafts are color-coded blue for exhaust and orange for intake.

  6.  
  7. Thoroughly clean and lubricate hydraulic tappets with clean engine oil. Install tappets to original bores is cylinder head.
  8.  
  9. Ensure mating faces of camshaft carrier and cylinder head are clean and dry.
  10.  
  11. Lubricate camshafts and bearing journals with clean engine oil.
  12.  
  13. Position camshafts in cylinder head with rear timing gear drive slots in each camshaft facing towards the center as shown.
  14.  
  15. Apply continuous thin beads of sealant STC 4600 to paths on camshaft carrier as shown. Spread sealant to an even film using a roller.
    CAUTION
    To avoid contamination, assembly should be completed immediately after application of sealant.

  16.  
  17. Position camshaft carrier, fit and progressively tighten bolts in the sequence shown to 7.5 ft. lbs. (10 Nm).
  18.  
  19. Noting that the front camshaft oil seals are black in color and the rear oil seals are red, fit new camshaft oil seals using LRT-12-203 and LRT -12-148A
    CAUTION
    Oil seal is waxed on outer diameter and must not be lubricated before fitting.

  20.  
  21. Clean camshaft timing belt cover backplate bolts and apply Loctite 242 to the first 3 threads.
  22.  
  23. Position camshaft timing belt rear cover backplates to cylinder head, fit and tighten bolts to 7 ft. lbs. (9 Nm).
  24.  
  25. Clean mating surfaces of camshaft cover and carrier.
  26.  
  27. Clean inside of camshaft cover. If necessary, wash oil separator elements in solvent and blow dry.
  28.  
  29. Position new gasket to camshaft carrier with arrows on gasket pointing towards inlet manifold.
  30.  
  31. Fit front and rear camshaft timing belts.
  32.  
  33. Check and refill fluids as necessary.
  34.  
  35. Connect the negative battery cable.
  36.  

 
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