Mazda B-Series 1998-06

Camshaft, Bearings & Lifters

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NOTE
Although Mazda suggests that this component is removable while the engine is installed in the vehicle, depending on the particular options with which your truck is equipped, working clearance may be extremely tight and this procedure may be much easier to perform with the engine removed. Before commencing, read through this procedure and make certain enough clearance, or working room, exists with the engine in the vehicle; if there is not enough space, the engine should be removed.

Bearing Replacement



If excessive camshaft wear is found, or if the engine is completely rebuilt, the camshaft bearings should be replaced. Use these service repair procedures as a guide.

2.3L And 2.5L Engines


Click image to see an enlarged view

Fig. Camshaft bearing installation on the 2.3L gasoline engine-2.5L engine similar

  1. Remove the head and place it on a work stand.
  2.  
  3. Remove the camshaft.
  4.  
  5. Using a tool such as Bearing Replacer T71P-6250-A, remove the bearings.
  6.  
  7. Coat the new bearings with clean 50W engine oil and install them with the tool.
  8.  

3.0L And 4.0L Engines
  1. Remove the engine and place it on a work stand.
  2.  
  3. Remove the flywheel.
  4.  
  5. Remove the camshaft.
  6.  
  7. Using a sharp punch and hammer, drive a hole in the rear bearing bore plug and pry it out.
  8.  
  9. Using the special tools and instructions in Cam Bearing Replacer Kit T65L-6250-A, or their equivalents, remove the bearings.
  10.  
  11. To remove the front bearing, install the tool from the rear of the block.
  12.  

To install:

  1. Following the instructions in the tool kit, install the bearings. Make sure that you follow the instructions carefully. Failure to use the correct expanding collets can cause severe bearing damage!
  2.  

Make sure that the oil holes in the bearings and block are aligned! Make sure that the front bearing is installed 0.51-0.89mm below the face of the block.

  1. Install a new bearing bore plug coated with sealer.
  2.  
  3. Install the camshaft.
  4.  
  5. Install the flywheel.
  6.  
  7. Install the engine.
  8.  

Inspection



Camshaft End Play


Click image to see an enlarged view

Fig. Checking camshaft end play with the cylinder head removed from the engine

2.3L And 2.5L Engines


Click image to see an enlarged view

Fig. Camshaft thrust plate installation on 2.3L and 2.5L engines

Remove the camshaft drive belt cover. Push the camshaft toward the rear of the engine. Install a dial indicator so that the indicator point is on the camshaft sprocket attaching screw or gear hub. Zero the dial indicator. Position a prybar between the camshaft sprocket or gear and the cylinder head. Pull the camshaft forward and release it. Compare the dial indicator reading with specifications. If the end play is excessive, replace the thrust plate at the rear of the cylinder head. Remove the dial indicator and install the camshaft drive belt cover. The camshaft end-play specification is 0.001-0.007 inch and the service limit is 0.003 inch. Camshaft specifications are sometimes modified by Mazda after production.

3.0L (B Series Pick-Up) And 4.0L Engines
  1. Push the camshaft toward the rear of the engine. Install a dial indicator (Tool D78P-4201-C or equivalent so that the indicator point is on the camshaft sprocket attaching screw.
  2.  
  3. Zero the dial indicator. Position a prybar between the camshaft gear and the block. Pull the camshaft forward and release it. Compare the dial indicator reading with the specification. The camshaft end-play specification is 0.0008-0.004 inch and the service limit is 0.009 inch (0.007 inch on 3.0L engine). Camshaft specifications are sometimes modified by Mazda after production.
  4.  
  5. If the end play is excessive, check the spacer for correct installation before it is removed. If the spacer is correctly installed, replace the thrust plate.
  6.  

The spacer ring and thrust plate are available in two thicknesses to permit adjusting the end play.

  1. Remove the dial indicator.
  2.  

Camshaft Lobe Lift
2.3L, 2.5L, 2.6L And 3.0L (MPV) Engines

Check the lift of each lobe in consecutive order and make a note of the readings. Camshaft assembly specifications are sometimes modified by Mazda after production. Refer to a local reputable machine shop as necessary.

  1. Remove the valve cover.
  2.  
  3. Measure the distance between the major (A-A) and minor (B-B) diameters of each cam lobe with a Vernier caliper and record the readings. The difference in the readings on each cam diameter is the lobe lift.
  4.  
  5. If the readings do not meet specifications, replace the camshaft and all rocker arms/cam followers.
  6.  
  7. Install the valve cover.
  8.  



Click image to see an enlarged view

Fig. Checking camshaft lobe lift

3.0L And 4.0L Engines

Check the lift of each lobe in consecutive order and make a note of the reading. Camshaft assembly specifications are sometimes modify by MAZDA after production. Refer to a local reputable machine shop as necessary.

  1. Remove the fresh air inlet tube and the air cleaner. Remove the heater hose and crankcase ventilation hoses. Remove valve rocker arm cover(s).
  2.  
  3. Remove the rocker arm stud nut or fulcrum bolts, fulcrum seat and rocker arm.
  4.  
  5. Make sure the push rod is in the valve tappet socket. Install a dial indicator D78P-4201-B (or equivalent) so that the actuating point of the indicator is in the push rod socket (or the indicator ball socket adapter Tool 6565-AB is on the end of the push rod) and in the same plane as the push rod movement.
  6.  
  7. Disconnect the I terminal and the S terminal at the starter relay. Install an auxiliary starter switch between the battery and S terminals of the starter relay. Crank the engine with the ignition switch off. Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe. At this position, the push rod will be in its lowest position.
  8.  
  9. Zero the dial indicator. Continue to rotate the crankshaft slowly until the push rod is in the fully raised position.
  10.  
  11. Compare the total lift recorded on the dial indicator with the specification. To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the lift on any lobe is below specified wear limits, the camshaft and the valve tappet operating on the worn lobe(s) must be replaced.
  12.  
  13. Remove the dial indicator and auxiliary starter switch.
  14.  
  15. Install the rocker arm, fulcrum seat and stud nut or fulcrum bolts.
  16.  
  17. Install the valve rocker arm covers and the air cleaner.
  18.  

Removal & Installation



2.3L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Properly discharge the A/C system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    The generator will be removed with the accessory bracket.


    NOTE
    There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head to access the bolt.


    NOTE
    Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.


    NOTE
    The oil pump chain sprocket must be held in place.


    NOTE
    Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.



    Negative battery cable
     
    Drive belt.
     
    Engine oil level indicator assembly.
     
    Engine oil level indicator.
     
    Engine oil level indicator tube.
     
    Water outlet tube.
     
    Water outlet tube.
     
    A/C compressor.
     



    Accessory bracket.
     
    Right motor mount.
     
    Coolant hose from the thermostat.
     
    Coolant hose from the EGR valve.
     
    Coolant tube assembly.
     
    Exhaust manifold and gasket.
     
    Block heater (if so equipped).
     
    Water outlet.
     
    EGR valve.
     
    Power steering pump and reservoir as an assembly.
     
    Idle air control (IAC) valve.
     
    Throttle position (TP) sensor.
     
    Manifold absolute pressure (MAP) sensor.
     
    Swirl control valve monitor electrical connector.
     
    CKP sensor and the wiring harness pin-type retainers.
     
    Knock sensor (KS).
     
    Electric thermostat.
     
    Swirl control valve.
     
    CMP sensor electrical connector and disconnect the PCV hose from the intake manifold.
     
    Engine wiring harness pin-type retainers from the intake manifold.
     
    Engine wiring harness connector bracket. Position the engine wiring harness aside.
     
    EGR tube.
     
    Fuel supply line clip from the front of the intake manifold. Disconnect the vacuum hose from the intake manifold.
     
    Intake manifold assembly.
     
    Fuel injector electrical connectors. Detach the wiring harness pin-type retainers.
     
    Ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.
     
    Engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
     
    Ignition coil.
     
    Bypass hose.
     
    Thermostat housing.
     
    Knock sensor and the engine vent cover.
     
    Left motor mount.
     
    Fuel injector supply manifold with the injectors and the ground strap.
     
    Water pump pulley.
     
    Water pump.
     
    CMP sensor.
     
    CHT sensor.
     
    Spark plugs.
     
    Valve cover.
     
    CKP sensor.
     
    Crankshaft vibration damper
     



    Front cover.
     
    Timing chain tensioner.
     
    Timing chain guides.
     
    Timing chain assembly.
     



    Camshaft drive sprockets.
     
    Oil pump chain tensioner and guide.
     



    Oil pump chain and sprockets.
     

  10.  
  11. Loosen the camshaft bearing cap bolts in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps.

    Click image to see an enlarged view

    Fig. Camshaft cap loosening sequence-2.3L

  12.  
  13. Remove the camshafts.

    Click image to see an enlarged view

    Fig. Camshaft cap torque sequence-2.3L

  14.  
  15. Installation is the reverse of removal.
    NOTE
    Install the camshafts with the alignment notches in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. Lubricate the camshaft journals and bearing caps with clean engine oil. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.



    Step 1: Tighten the camshaft bearing caps one turn at a time until tight.
     
    Step 2: Tighten the bolts to 7 Nm (62 inch lbs.)
     
    Step 3: Tighten the bolts to 16 Nm (12 ft. lbs.)
     

    1. Crankshaft vibration damper:
      NOTE
      Do not reuse the crankshaft pulley bolt. Tighten the bolt in two stages.



      Step 1: Tighten the bolt to 40 Nm (30 ft. lbs.)
       
      Step 2: Tighten the bolt and additional 90 degrees (1/4 turn).
       

    2.  

  16.  


NOTE
On some engines the crankshaft, crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe damage can occur.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Drain the cooling system.
  8.  
  9. Properly discharge the air conditioning system.
  10.  
  11. Remove or disconnect the following:
    NOTE
    The alternator will be removed with the accessory bracket.


    NOTE
    There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head to access the bolt.


    NOTE
    Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.


    NOTE
    The oil pump chain sprocket must be held in place


    NOTE
    Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.



    Drive belt.
     
    Engine oil level indicator assembly.
     
    Engine oil level indicator.
     
    Engine oil level indicator tube.
     
    Water outlet tube.
     
    Water outlet tube.
     
    Air conditioning compressor.
     



    Accessory bracket
     
    Right motor mount.
     
    Coolant hose from the thermostat
     
    Coolant hose from the EGR valve
     
    Coolant tube assembly
     
    Exhaust manifold and gasket
     
    Block heater (if so equipped)
     
    Water outlet
     
    EGR valve
     
    Power steering pump and reservoir as an assembly
     
    Idle air control (IAC) valve
     
    Throttle position (TP) sensor
     
    Manifold absolute pressure (MAP) sensor
     
    Swirl control valve monitor electrical connector
     
    CKP sensor and the wiring harness pin-type retainers
     
    Knock sensor (KS)
     
    Electric thermostat
     
    Swirl control valve
     
    CMP sensor electrical connector and disconnect the PCV hose from the intake manifold
     
    Engine wiring harness pin-type retainers from the intake manifold
     
    Engine wiring harness connector bracket. Position the engine wiring harness aside
     
    EGR tube
     
    Fuel supply line clip from the front of the intake manifold. Disconnect the vacuum hose from the intake manifold
     
    Intake manifold assembly
     
    Fuel injector electrical connectors. Detach the wiring harness pin-type retainers
     
    Ignition coil and the cylinder head temperature (CHT) sensor electrical connectors
     
    Engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness
     
    Ignition coil
     
    Bypass hose
     
    Thermostat housing
     
    Knock sensor and the engine vent cover
     
    Left motor mount
     
    Fuel injector supply manifold with the injectors and the ground strap
     
    Water pump pulley
     
    Water pump
     
    CMP sensor
     
    CHT sensor
     
    Spark plugs
     
    Valve cover
     
    CKP sensor
     
    Crankshaft vibration damper
     



    Front cover
     
    Timing chain tensioner
     
    Timing chain guides
     
    Timing chain assembly
     



    Camshaft drive sprockets
     
    Oil pump chain tensioner and guide
     



    Oil pump chain and sprockets
     

  12.  
  13. Loosen the camshaft bearing cap bolts in sequence, one turn at a time. Repeat the first step until all tension is released from the camshaft bearing caps. Remove the camshaft bearing caps.

    Click image to see an enlarged view

    Fig. Camshaft cap loosening sequence-2.3L engine

  14.  
  15. Remove the camshafts.

    Click image to see an enlarged view

    Fig. Camshaft cap torque sequence-2.3L engine

  16.  

To install:

  1. Installation is the reverse of removal.
    NOTE
    Install the camshafts with the alignment notches in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons. Lubricate the camshaft journals and bearing caps with clean engine oil. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.



    Step 1: Tighten the camshaft bearing caps one turn at a time until tight.
     
    Step 2: Tighten the bolts to 7 Nm (62 inch lbs.)
     
    Step 3: Tighten the bolts to 16 Nm (12 ft. lbs.)
     

    1. Crankshaft vibration damper:
      NOTE
      Do not reuse the crankshaft pulley bolt. Tighten the bolt in two stages.



      Step 1: Tighten the bolt to 40 Nm (30 ft. lbs.)
       
      Step 2: Tighten the bolt and additional 90 degrees (1/4 turn).
       

    2.  

  2.  

2.5L Engine
  1. Drain the cooling system.
  2.  
  3. Before servicing the vehicle, refer to the Precautions section.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner
     
    Spark plug wires and retainers
     
    Vacuum lines
     
    Drive belts
     
    Alternator and bracket
     
    Upper radiator hose
     
    Radiator shroud
     
    Fan blades
     
    Water pump pulley
     
    Fan shroud
     

  6.  
  7. Align the engine timing marks at Top Dead Center (TDC) for No. 1 cylinder. Remove the timing belt.

    Valve covers
     
    Rocker arms (camshaft followers)
     
    Camshaft drive gear and belt guide using a suitable puller. Remove the front oil seal with Front Seal Replacer T74P-6150-A
     
    Camshaft retainer located on the rear mounting stand
     
    Front motor mount bolts
     
    Lower radiator hose from the radiator
     
    Automatic transmission cooler lines, if equipped
     

  8.  
  9. Position a piece of wood on a floor jack and raise the engine carefully as far as it will go. Place blocks of wood between the engine mounts and crossmember pedestals.
  10.  
  11. Remove the camshaft by carefully withdrawing it toward the front of the engine. Caution should be used to prevent damage to cam bearings, lobes and journals.
  12.  
  13. Check the camshaft journals and lobes for wear. Inspect the cam bearings, if worn (unless the proper bearing installing tool is on hand), the cylinder head must be removed for new bearings to be installed by a machine shop.
  14.  

To install:

  1. Install or connect the following:

    Camshaft and lower the engine to its original position
     
    Transmission cooler lines, if equipped
     
    Lower radiator hose
     
    Front motor mount. Torque the bolts to 65 ft. lbs. (88 Nm).
     
    Camshaft retainer on the rear mounting stand
     
    Camshaft drive gear and belt guide
     
    Valve covers
     
    Timing belt. Make certain that the timing marks are properly aligned
     
    Fan shroud
     
    Water pump pulley
     
    Fan blades
     
    Upper radiator hose and radiator shroud
     
    Alternator and bracket
     
    Drive belts
     
    Vacuum lines
     
    Spark plugs wires and retainers
     
    Air cleaner
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks, repair if necessary.
  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Evacuate the A/C system.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner hoses
     
    Fan, spacer and shroud
     
    Radiator
     

  12.  
  13. Rotate the crankshaft so that No. 1 piston is at Top Dead Center (TDC) on the compression stroke.

    A/C condenser
     
    Fuel lines from the fuel supply manifold
     
    Vacuum hoses
     
    Electrical wiring
     
    Engine front cover
     
    Water pump
     
    Alternator
     
    Power steering pump. Do not disconnect the hoses
     
    A/C compressor. Do not disconnect the hoses
     
    Throttle body
     
    Fuel injection wire harness
     

  14.  
  15. Turn the engine by hand to TDC of the power stroke on No. 1 cylinder.

    Spark plug wires from the plugs
     
    Distributor cap with the spark plug wires as an assembly, if equipped
     

  16.  
  17. Matchmark the rotor, distributor body and engine. Disconnect the distributor wiring harness and remove the distributor, if equipped.

    Rocker arm covers
     
    Intake manifold
     
    Loosen the rocker arm bolts enough to pivot the rocker arms out of the way and remove the pushrods. Identify them for installation
     
    Lifters and identify them for installation
     
    Crankshaft pulley/damper
     
    Starter
     
    Oil pan
     
    Camshaft gear attaching bolt and washer, then slide the gear off the camshaft
     
    Camshaft thrust plate
     

  18.  
  19. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings.
  20.  

To install:

  1. Oil the camshaft journals and cam lobes with heavy SJ engine oil (50W). Install the spacer ring with the chamfered side toward the camshaft, then insert the camshaft key.
  2.  
  3. Install or connect the following:

    Camshaft using caution to avoid any damage to the camshaft bearings
     
    Thrust plate. Torque the screws to 84 inch lbs. (10 Nm).
     

  4.  
  5. Rotate the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft gear and chain. Torque the bolt to 46 ft. lbs. (62 Nm).
  6.  
  7. Coat the tappets with 50W engine oil and place them in their original locations.
  8.  
  9. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations.
  10.  
  11. Pivot the rocker arms into position. Torque the fulcrum bolts to 96 inch lbs. (11 Nm).
  12.  
  13. Rotate the engine until both timing marks are at the top of their sprockets and aligned. Torque the following fulcrum bolts to 18 ft. lbs. (24 Nm):
    1. No.1 intake.
    2.  
    3. No.2 exhaust.
    4.  
    5. No.4 intake.
    6.  
    7. No.5 exhaust.
    8.  

  14.  
  15. Rotate the engine until the camshaft timing mark is at the bottom of the sprocket and the crankshaft timing mark is at the top of the sprocket, and both are aligned. Torque the following fulcrum bolts to 18 ft. lbs. (24 Nm):
    1. No.1 exhaust.
    2.  
    3. No.2 intake.
    4.  
    5. No.3 intake and exhaust.
    6.  
    7. No.4 exhaust.
    8.  
    9. No.5 intake.
    10.  
    11. No.6 intake and exhaust.
    12.  

  16.  
  17. Torque all the bolts to 24 ft. lbs. (33 Nm).
  18.  
  19. Turn the engine by hand to 0 degrees Before Top Dead center (BTDC) of the power stroke on No. 1 cylinder.
  20.  
  21. Install or connect the following:

    Engine front cover and water pump assembly
     
    Oil pan
     
    Crankshaft damper/pulley and tighten the retaining bolt to 107 ft. lbs. (145 Nm).
     
    Intake manifold
     
    Starter
     
    Crankshaft pulley and damper
     
    Rocker arm covers
     
    Rotor and distributor cap, if equipped
     
    Spark plug wires
     
    Fuel lines to the fuel supply manifold
     
    Fuel injection wire harness
     
    Throttle body
     
    A/C compressor
     
    Power steering pump
     
    Alternator
     
    Water pump
     
    Engine front cover
     
    All electrical connectors and vacuum lines
     
    A/C condenser
     
    Radiator
     
    Fan, spacer and shroud
     
    Air cleaner hoses
     
    Negative battery cable
     

  22.  
  23. Recharge the A/C system.
  24.  
  25. Refill the cooling system.
  26.  
  27. Replace the oil filter and refill the engine with the specified amount of engine oil.
  28.  
  29. Start the engine and check the ignition timing and idle speed. Adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks.
  30.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Drain the cooling system.
  8.  
  9. Drain the engine oil.
  10.  
  11. Evacuate the air conditioning system.
  12.  
  13. Remove or disconnect the following:

    Air cleaner hoses
     
    Fan, spacer and shroud
     
    Radiator
     

  14.  
  15. Rotate the crankshaft so that No. 1 piston is at Top Dead Center (TDC) on the compression stroke.

    Air conditioning condenser
     
    Fuel lines from the fuel supply manifold
     
    Vacuum hoses
     
    Electrical wiring
     
    Engine front cover
     
    Water pump
     
    Alternator
     
    Power steering pump. Do not disconnect the hoses
     
    Air conditioning compressor. Do not disconnect the hoses
     
    Throttle body
     
    Fuel injection wire harness
     

  16.  
  17. Turn the engine by hand to TDC of the power stroke on No. 1 cylinder.

    Spark plug wires from the plugs
     
    Rocker arm covers
     
    Intake manifold
     
    Loosen the rocker arm bolts enough to pivot the rocker arms out of the way and remove the pushrods. Identify them for installation
     
    Lifters and identify them for installation
     
    Crankshaft pulley/damper
     
    Starter
     
    Oil pan
     
    Camshaft gear attaching bolt and washer, then slide the gear off the camshaft
     
    Camshaft thrust plate
     

  18.  
  19. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings.
  20.  

To install:

  1. Oil the camshaft journals and cam lobes with heavy SJ engine oil (50W). Install the spacer ring with the chamfered side toward the camshaft, then insert the camshaft key.
  2.  
  3. Install or connect the following:

    Camshaft using caution to avoid any damage to the camshaft bearings
     
    Thrust plate. Torque the screws to 84 inch lbs. (10 Nm).
     

  4.  
  5. Rotate the camshaft and crankshaft as necessary to align the timing marks. Install the camshaft gear and chain. Torque the bolt to 46 ft. lbs. (62 Nm).
  6.  
  7. Coat the tappets with 50W engine oil and place them in their original locations.
  8.  
  9. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations.
  10.  
  11. Pivot the rocker arms into position. Torque the fulcrum bolts to 96 inch lbs. (11 Nm).
  12.  
  13. Rotate the engine until both timing marks are at the top of their sprockets and aligned. Torque the following fulcrum bolts to 18 ft. lbs. (24 Nm):
    1. No.1 intake.
    2.  
    3. No.2 exhaust.
    4.  
    5. No.4 intake.
    6.  
    7. No.5 exhaust.
    8.  

  14.  
  15. Rotate the engine until the camshaft timing mark is at the bottom of the sprocket and the crankshaft timing mark is at the top of the sprocket, and both are aligned. Torque the following fulcrum bolts to 18 ft. lbs. (24 Nm):
    1. No.1 exhaust.
    2.  
    3. No.2 intake.
    4.  
    5. No.3 intake and exhaust.
    6.  
    7. No.4 exhaust.
    8.  
    9. No.5 intake.
    10.  
    11. No.6 intake and exhaust.
    12.  

  16.  
  17. Torque all the bolts to 24 ft. lbs. (33 Nm).
  18.  
  19. Turn the engine by hand to 0 degrees Before Top Dead center (BTDC) of the power stroke on No. 1 cylinder.
  20.  
  21. Install or connect the following:

    Engine front cover and water pump assembly
     
    Oil pan
     
    Crankshaft damper/pulley and tighten the retaining bolt to 107 ft. lbs. (145 Nm).
     
    Intake manifold
     
    Starter
     
    Crankshaft pulley and damper
     
    Rocker arm covers
     
    Spark plug wires
     
    Fuel lines to the fuel supply manifold
     
    Fuel injection wire harness
     
    Throttle body
     
    Air conditioning compressor
     
    Power steering pump
     
    Alternator
     
    Water pump
     
    Engine front cover
     
    All electrical connectors and vacuum lines
     
    Air conditioning condenser
     
    Radiator
     
    Fan, spacer and shroud
     
    Air cleaner hoses
     
    Negative battery cable
     

  22.  
  23. Recharge the air conditioning system.
  24.  
  25. Refill the cooling system.
  26.  
  27. Replace the oil filter and refill the engine with the specified amount of engine oil.
  28.  
  29. Start the engine and check the ignition timing and idle speed. Adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks.
  30.  

4.0L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Remove the valve covers. Remove the fuel supply manifold.
    NOTE
    Mark each camshaft roller follower to ensure its original position during reassembly.

  8.  
  9. Using tool 303-581, remove the roller followers.
  10.  
  11. Remove the intake manifold. Remove the thermostat housing.
  12.  
  13. Remove the hydraulic chain tensioner.

    Click image to see an enlarged view

    Fig. Left side hydraulic chain tensioner location-4.0L engine

  14.  
  15. On 2006 vehicles, install camshaft sprocket holding tool 303-564 and 303-578 on the front of the camshaft.
  16.  
  17. Loosen and remove the camshaft sprocket bolt. Position the camshaft sprocket aside.
    NOTE
    Mark the position of the camshaft bearing caps so that they can be reinstalled in their original positions.

  18.  
  19. Remove the bolts in the proper sequence and remove the bearing caps.
  20.  
  21. If equipped, remove the oil supply tube.
  22.  
  23. Remove the camshaft.
  24.  

To install:

  1. Lubricate all of the moving parts with SAE 50W engine oil.
  2.  
  3. Install camshaft onto the cylinder head.
  4.  
  5. Position the oil rail, if equipped and install the bearing caps and bolts. Torque the bolts in 2 steps:
    1. Step 1-53.5 inch lbs. (6 Nm).
      NOTE
      The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.

    2.  

  6.  
  7. Install the camshaft sprocket and loosely install the bolt.
    NOTE
    The camshafts must be retimed or engine damage may occur.

  8.  
  9. Retime the camshafts.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.
  12.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.

  6.  
  7. Remove the valve covers. Remove the fuel supply manifold.
    NOTE
    Mark each camshaft roller follower to ensure its original position during reassembly.

  8.  
  9. Using tool 303-581, remove the roller followers.
  10.  
  11. On 2002-2005 vehicles remove the tire and wheel assembly. Remove the lower splash shield.
  12.  
  13. Remove the hydraulic chain tensioner.

    Click image to see an enlarged view

    Fig. Right side hydraulic chain tensioner location-4.0L engine

  14.  
  15. Install camshaft sprocket holding tool, 303-575 or equivalent on the rear of the cylinder head.
    NOTE
    The camshaft sprocket is a left hand threaded bolt pattern.

  16.  
  17. Loosen and remove the camshaft sprocket bolt. Position the camshaft sprocket aside.
    NOTE
    Mark the position of the camshaft bearing caps so that they can be reinstalled in their original positions.

  18.  
  19. Remove the bolts in the proper sequence and remove the bearing caps.
  20.  
  21. If equipped, remove the oil supply tube.
  22.  
  23. Remove the camshaft.
  24.  

To install:

  1. Lubricate all of the moving parts with SAE 50W engine oil.
  2.  
  3. Install camshaft onto the cylinder head.
  4.  
  5. Position the oil rail, if equipped and install the bearing caps and bolts. Torque the bolts in 2 steps:
    1. Step 1-53.5 inch lbs. (6 Nm).
      NOTE
      The camshaft gear must turn freely on the camshaft. Do not tighten the bolt at this time.

    2.  

  6.  
  7. Install the camshaft sprocket and loosely install the bolt.
    NOTE
    The camshafts must be retimed or engine damage may occur.

  8.  
  9. Retime the camshafts.
  10.  
  11. Continue the installation in the reverse order of the removal procedure.

    Click image to see an enlarged view

    Fig. Camshaft bolt removal sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Camshaft bolt torque sequence-4.0L engine

  12.  

4.0L Ohv Engines

NOTE
It is necessary to replace the oil pan gasket when removing and installing the engine front cover. It will also be necessary to remove the transmission to properly reseal the oil pan.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Evacuate the A/C system.
  8.  
  9. Relieve fuel system pressure.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Radiator
     
    A/C compressor. Do not disconnect the lines
     
    A/C condenser
     
    Fan, spacer and shroud
     
    Air cleaner hoses
     
    Spark plug wires
     
    Ignition coil and bracket
     
    Crankcase pulley and damper
     
    Oil pump drive
     
    Alternator
     
    Fuel lines at the supply manifold
     
    Upper and lower intake manifold
     
    Rocker arm covers
     
    Rocker arm shafts
     
    Pushrods and identify them for installation
     
    Tappets and identify them for installation
     
    Oil pan
     
    Engine front cover
     
    Water pump
     

  12.  
  13. Turn the engine by hand until the timing marks align at Top dead Center (TDC) of the power stroke on No.1 piston.
  14.  
  15. Place the timing chain tensioner in the retracted position and install the retaining clip.
  16.  
  17. Check the camshaft end-play. If excessive, you'll have to replace the thrust plate.
  18.  
  19. Remove the camshaft gear attaching bolt and washer, then slide the gear off the camshaft.
  20.  
  21. Remove the camshaft thrust plate.
  22.  
  23. Carefully slide the camshaft out of the engine block, using caution to avoid any damage to the camshaft bearings.
  24.  

To install:

  1. Lubricate the camshaft using a good assembly lubricant.
  2.  
  3. Install or connect the following:

    Camshaft using caution to avoid any damage to the camshaft bearings
     
    Thrust plate. Make sure that it covers the main oil gallery. Torque the screws to 84-120 inch lbs. (9-13 Nm).
     

  4.  
  5. Rotate the camshaft and crankshaft, as necessary, to align the timing marks.

    Camshaft gear and chain. Torque the bolt to 44-50 ft. lbs. (60-68 Nm).
     

  6.  
  7. Remove the clip from the chain tensioner

    Engine front cover and water pump
     
    Crankshaft damper/pulley. Torque the bolt to 107 ft. lbs. (146 Nm).
     
    Oil pan
     

  8.  
  9. Coat the tappets with 50W engine oil and place them in their original locations.
  10.  
  11. Apply 50W engine oil to both ends of the pushrods. Install the pushrods in their original locations.

    Tappets
     
    Rocker arm shafts and covers
     
    Upper and lower intake manifolds
     
    Fuel lines to the fuel supply manifold
     
    Alternator and electrical connectors
     
    Oil pump drive
     
    Crankcase pulley and damper
     
    Ignition coil and bracket
     
    Spark plug wires
     
    Air cleaner hoses
     
    Fan, spacer and shroud
     
    A/C condenser
     
    A/C compressor
     
    Radiator
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Recharge the A/C system.
  16.  
  17. Replace the oil filter and refill the engine with clean oil.
  18.  
  19. Start the engine and check the ignition timing and idle speed; adjust if necessary. Run the engine at fast idle and check for coolant, fuel, vacuum or oil leaks.
  20.  

4.0L SOHC Engine


Click image to see an enlarged view

Fig. Use the proper sequence to prevent damage to the camshaft both when installing and removing the bearing caps-4.0L SOHC engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    The right-hand camshaft sprocket bolt uses left-hand threads.



    Negative battery cable for safety
     
    Valve cover
     
    Hydraulic camshaft tensioner
     

  4.  
  5. For the right-hand camshaft use the Cam Gear Torque Adapter tool T97T-6256-F, to remove the camshaft sprocket bolt.
  6.  
  7. For the left-hand camshaft, remove the sprocket bolt.
    NOTE
    When removing the followers, label them so that they may be returned to their original positions.

  8.  
  9. Using the Valve Spring Compressor tool ST1330-A, remove the camshaft roller followers.
  10.  
  11. Install or connect the following:

    Camshaft bearing cap bolts and the oil rail
     
    Camshaft
     

  12.  

To install:

  1. Lubricate all of the moving parts with SAE 50W engine oil.
  2.  
  3. Install camshaft onto the cylinder head.
  4.  
  5. Position the oil rail and install the bearing caps and bolts. Torque the bolts in 2 steps:
    1. Step 1-53.5 inch lbs. (6 Nm).
    2.  
    3. Step 2-11-12.5 ft. lbs. (15-17 Nm).
    4.  

  6.  
  7. Install or connect the following:

    Camshaft followers
     
    Camshaft sprocket bolt and hand tighten the bolt
     
    Camshaft Chain Tensioner T97T-6K254-A in the hole that the hydraulic chain tensioner was in
     

  8.  
  9. Turn the crankshaft one revolution clockwise until No. 1 piston is Top Dead Center (TDC).
  10.  
  11. Install or connect the following:

    Crankshaft Holding tool T97T-6303-A on the crankshaft to keep it from turning
     
    Position the timing slot on the rear of the camshaft to fit Camshaft Holding tool T97T-6256-C and install the holding tool on the rear of the head
     
    Camshaft Gear Holding tool T97T-6256-B and Camshaft Gear Holding tool T97T-6256-A on the front of the cylinder head to securely hold the camshaft gear
     
    Tighten the camshaft sprocket bolt to 63 ft. lbs. (85 Nm).
     

  12.  
  13. Remove the Camshaft Chain Tensioner tool and install the hydraulic chain tensioner, tighten the tensioner to 35-39 ft. lbs. (47-53 Nm).
  14.  
  15. Remove the special tools from the engine.
  16.  
  17. Install or connect the following:

    Valve cover
     
    Negative battery cable
     

  18.  
  19. Start the engine check for leaks and repair if necessary.
  20.  

 
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