Nissan Car 350Z & Maxima 1999-06

Camshaft, Bearings & Lifters 1

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Removal & Installation



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



    Negative battery cable
     
    Left side rocker cover ornament
     



    Air duct to intake manifold hose, collector hose, blow-by hose and vacuum hoses
     
    Fuel hoses and detach the harness connections
     
    Canister purge hoses
     
    Water hoses from the cylinder head and intake manifold
     
    All 6 ignition coils from the spark plugs
     
    Spark plugs
     
    Bolts that secure the Exhaust Gas Recirculation (EGR) tube
     
    EGR tube
     
    Intake manifold collector supports and the collector
     
    Bolts that secure the fuel tube and the fuel tube
     
    Bolts that secure the intake manifold to the engine block and the manifold. Loosen the bolts in the reverse sequence of the tightening procedure
     
    Left-hand and right-hand rocker covers from the cylinder head
     
    Engine undercovers
     
    Right front wheel and engine side covers
     
    Drive belts and idler pulley
     
    Power steering oil pump belt and the power steering oil pump assembly
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
     

  10.  
  11. Set the No. 1 piston to Top Dead Center (TDC) of compression stroke by rotating the crankshaft.
  12.  
  13. Remove or disconnect the following:

    Ring gear cover access plate. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate
     
    Crankshaft pulley, using a suitable puller
     
    Air conditioning compressor and bracket
     
    Front exhaust pipe and its support
     

  14.  
  15. Hang the engine at the right and left side engine slingers with a suitable hoist.
  16.  
  17. Support the transaxle with jack.
  18.  
  19. Remove or disconnect the following:

    Right side engine mounting, mounting bracket and nuts
     
    Center crossmember assembly
     
    Steel (lower) oil pan bolts in the reverse of the installation sequence
     

  20.  
  21. Insert a seal cutter between the steel and aluminum oil pan
  22.  
  23. Tapping the cutter with a hammer, slide it around the entire edge of the oil pan. Be careful not to damage the aluminum mating surface of the upper oil pan.
  24.  
  25. Remove or disconnect the following:

    Steel oil pan and the oil strainer
     
    Aluminum (upper) oil pan bolts in the reverse of the installation sequence
     
    Transaxle bolts that secure the oil pan
     

  26.  
  27. Insert a seal cutter between the aluminum oil pan and the engine block.
  28.  
  29. Tapping the cutter with a hammer, slide it around the entire edge of the oil pan. Be careful not to damage the mating surfaces of the oil pan or engine block.

    Oil pan from the vehicle
     
    Water pump cover and the bolts that secure the front timing chain case cover
     
    Timing chain case cover, using the seal cutter
     
    Internal timing chain guide and the upper chain guide
     
    Timing chain tensioner and slack side chain guide
     
    Left and right intake camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts
     
    Lower timing chain assembly. Be sure to note the aligning marks of the chain before removal
     

  30.  
  31. Insert a suitable stopper pin for the left and right camshaft tensioners.
  32.  
  33. Remove or disconnect the following:
    NOTE
    Remove the O-rings from the front of the engine block.


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


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



    Left and right exhaust camshaft sprocket bolts. Be sure to hold the flats of the camshafts while removing the sprocket bolts
     
    Upper timing chain assembly. Be sure to note the aligning marks of the chain before removal
     
    Lower timing chain guide
     
    Crankshaft sprocket
     
    Bolts that secure the rear timing chain case. The bolts must be loosened in sequence
     
    Rear timing case cover, using the seal cutter
     



    Camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence
     



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



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

  34.  
  35. Check the diameter of the valve lifter and the valve lifter guide bore.
  36.  
  37. The diameter of the lifter should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021mm).
  38.  
  39. Remove all traces of liquid gasket from the timing chain case and from the water pump covers.
  40.  
  41. Remove all traces of liquid gasket from the engine block.
  42.  
  43. Inspect the camshafts for excessive wear or damage and replace as necessary.
  44.  

To install:

Click image to see an enlarged view

Fig. Camshaft identification marks-3.0L engines


NOTE
Before installing the camshaft brackets, apply RTV sealant to the mating surface of the No. 1 journal head.

  1. Lubricate the valve lifters with clean engine oil and install the lifters into the bore from which they were removed.
  2.  
  3. Lubricate the valve lifter shims with clean engine oil and install the shims into the lifter from which they were removed.
  4.  
  5. Turn the crankshaft clockwise until the No. 1 piston is set 240 degrees before TDC on compression stroke.
  6.  
  7. Install or connect the following:
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.


    NOTE
    When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



    Camshaft tensioners on both sides of the cylinder heads and torque the bolts to 75-96 inch lbs. (8.4-10.8 Nm)
     



    Click image to see an enlarged view

    Fig. Right cylinder head camshaft bearing cap tightening sequence-3.0L engines



    Click image to see an enlarged view

    Fig. Left cylinder head camshaft bearing cap tightening sequence-3.0L engines



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

  8.  
  9. Torque the camshaft bearing caps as follows:
    1. Bolts No. 7-10: 17 inch lbs. (2 Nm).
    2.  
    3. Bolts No. 1-6: 17 inch lbs. (2 Nm).
    4.  
    5. Bolts No. 1-10: 52 inch lbs. (6 Nm).
    6.  
    7. Bolts No. 1-10: 81-104 inch lbs. (9-11 Nm).
    8.  

  10.  
  11. Install new O-rings to the front of the engine block.
  12.  
  13. Apply sealant to the hatched portion of the of the rear timing chain case.
  14.  
  15. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block.
  16.  
  17. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).
  18.  
  19. Install the crankshaft sprocket with the mating mark facing out.
  20.  
  21. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head.
  22.  
  23. Install the lower chain guide on the dowel pin with the front mark on the guide facing upward.
  24.  
  25. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
  26.  
  27. Put the exhaust camshaft sprockets onto the dowel pin and torque the bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.
  28.  
  29. Install or connect the following:

    Timing chains, sprockets and related components
     
    Transaxle bolts that secure the oil pan
     
    Oil pan strainer and torque the bolts to 12-14 ft. lbs. (16-19 Nm)
     

  30.  
  31. Apply a 0.177-0.217 in. (4.5-5.5mm) continuous bead of liquid gasket to the lower oil pan mating surface and install the oil pan. Torque the bolts in sequence to 57-66 inch lbs. (6.4-7.5 Nm).
  32.  
  33. Install or connect the following:

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     

  34.  
  35. Remove the engine slinger assembly.
  36.  
  37. Install or connect the following:

    Front exhaust pipe and its support
     
    Air conditioning compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt. Torque the bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66 degrees clockwise. This is about the angle from one hexagon bolt head corner to another
     
    CMP sensor, PHASE and CKP sensors
     
    Power steering pump
     
    Idler pulley and all belts
     
    Engine side and under covers
     
    Right front wheel
     
    Intake manifold
     
    Rocker covers
     
    Fuel tube
     
    Intake manifold support and collector
     
    EGR tube
     
    Spark plugs and ignition coils
     
    Coolant hoses
     
    Canister purge hoses
     
    Fuel feed and return lines
     
    Vacuum hoses
     
    Negative battery cable
     

  38.  
  39. Fill the cooling system.
  40.  
  41. Fill the engine with clean oil.
  42.  
  43. Start the vehicle, check for leaks and repair if necessary.
  44.  

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



    Negative battery cable
     
    Left side rocker cover ornament
     



    Air duct to intake manifold hose, collector hose, blow-by hose and vacuum hoses
     
    Fuel hoses and detach the harness connections
     
    Canister purge hoses
     
    Water hoses from the cylinder head and intake manifold
     
    All 6 ignition coils from the spark plugs
     
    Spark plugs
     
    Bolts that secure the Exhaust Gas Recirculation (EGR) tube
     
    EGR tube
     
    Intake manifold collector supports and the collector
     
    Bolts that secure the fuel tube and the fuel tube
     
    Bolts that secure the intake manifold to the engine block and the manifold. Loosen the bolts in the reverse sequence of the tightening procedure.
     
    Left-hand and right-hand rocker covers from the cylinder head
     
    Engine undercovers
     
    Right front wheel and engine side covers
     
    Drive belts and idler pulley
     
    Power steering oil pump belt and the power steering oil pump assembly
     
    Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
     

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

    Ring gear cover access plate. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate
     
    Crankshaft pulley, using a suitable puller
     
    Air conditioning compressor and bracket
     
    Front exhaust pipe and its support
     

  12.  
  13. Hang the engine at the right and left side engine slingers with a suitable hoist.
  14.  
  15. Support the transaxle with jack.

    Right side engine mounting, mounting bracket and nuts
     
    Center crossmember assembly
     
    Steel (lower) oil pan bolts in the reverse of the installation sequence
     

  16.  
  17. Insert a seal cutter between the steel and aluminum oil pan
  18.  
  19. Tapping the cutter with a hammer, slide it around the entire edge of the oil pan. Be careful not to damage the aluminum mating surface of the upper oil pan.

    Steel oil pan and the oil strainer
     
    Aluminum (upper) oil pan bolts in the reverse of the installation sequence
     
    Transaxle bolts that secure the oil pan
     

  20.  
  21. Insert a seal cutter between the aluminum oil pan and the engine block.
  22.  
  23. Tapping the cutter with a hammer, slide it around the entire edge of the oil pan. Be careful not to damage the mating surfaces of the oil pan or engine block.

    Oil pan from the vehicle
     
    Water pump cover and the bolts that secure the front timing chain case cover
     
    Timing chain case cover, using the seal cutter
     
    Internal timing chain guide and the upper chain guide
     
    Timing chain tensioner and slack side chain guide
     
    Left and right intake camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
     
    Lower timing chain assembly. Be sure to note the aligning marks of the chain before removal.
     

  24.  
  25. Insert a suitable stopper pin for the left and right camshaft tensioners.
    NOTE
    Remove the O-rings from the front of the engine block.


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


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



    Left and right exhaust camshaft sprocket bolts. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
     
    Upper timing chain assembly. Be sure to note the aligning marks of the chain before removal.
     
    Lower timing chain guide
     
    Crankshaft sprocket
     
    Bolts that secure the rear timing chain case. The bolts must be loosened in sequence.
     
    Rear timing case cover, using the seal cutter
     



    Camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
     



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



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

  26.  
  27. Check the diameter of the valve lifter and the valve lifter guide bore.
  28.  
  29. The diameter of the lifter should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021mm).
  30.  
  31. Remove all traces of liquid gasket from the timing chain case and from the water pump covers.
  32.  
  33. Remove all traces of liquid gasket from the engine block.
  34.  
  35. Inspect the camshafts for excessive wear or damage and replace as necessary.
  36.  

To install:

Click image to see an enlarged view

Fig. Camshaft identification marks-3.5L engines


NOTE
Before installing the camshaft brackets, apply RTV sealant to the mating surface of the No. 1 journal head.

  1. Lubricate the valve lifters with clean engine oil and install the lifters into the bore from which they were removed.
  2.  
  3. Lubricate the valve lifter shims with clean engine oil and install the shims into the lifter from which they were removed.
  4.  
  5. Turn the crankshaft clockwise until the No. 1 piston is set 240 degrees before TDC on compression stroke.
  6.  
  7. Install or connect the following:
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.


    NOTE
    When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.



    Camshaft tensioners on both sides of the cylinder heads and torque the bolts to 75-96 inch lbs. (8.4-10.8 Nm)
     



    Click image to see an enlarged view

    Fig. Right cylinder head camshaft bearing cap tightening sequence-3.5L engine



    Click image to see an enlarged view

    Fig. Left cylinder head camshaft bearing cap tightening sequence-3.5L engine



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

  8.  
  9. Torque the camshaft bearing caps as follows:
    1. Bolts No. 7-10: 17 inch lbs. (2 Nm).
    2.  
    3. Bolts No. 1-6: 17 inch lbs. (2 Nm).
    4.  
    5. Bolts No. 1-10: 52 inch lbs. (6 Nm).
    6.  
    7. Bolts No. 1-10: 81-104 inch lbs. (9-11 Nm).
    8.  

  10.  
  11. Install new O-rings to the front of the engine block.
  12.  
  13. Apply sealant to the hatched portion of the of the rear timing chain case.
  14.  
  15. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block.
  16.  
  17. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).
  18.  
  19. Install the crankshaft sprocket with the mating mark facing out.
  20.  
  21. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head.
  22.  
  23. Install the lower chain guide on the dowel pin with the front mark on the guide facing upward.
  24.  
  25. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
  26.  
  27. Put the exhaust camshaft sprockets onto the dowel pin and torque the bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.
  28.  
  29. Install or connect the following:

    Timing chains, sprockets and related components
     
    Transaxle bolts that secure the oil pan
     
    Oil pan strainer and torque the bolts to 12-14 ft. lbs. (16-19 Nm)
     

  30.  
  31. Apply a 0.177-0.217 in. (4.5-5.5mm) continuous bead of liquid gasket to the lower oil pan mating surface and install the oil pan. Torque the bolts in sequence to 57-66 inch lbs. (6.4-7.5 Nm).

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     

  32.  
  33. Remove the engine slinger assembly.

    Front exhaust pipe and its support
     
    Air conditioning compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt. Torque the bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66 degrees clockwise. This is about the angle from one hexagon bolt head corner to another
     
    CMP sensor, PHASE and CKP sensors
     
    Power steering pump
     
    Idler pulley and all belts
     
    Engine side and under covers
     
    Right front wheel
     
    Intake manifold
     
    Rocker covers
     
    Fuel tube
     
    Intake manifold support and collector
     
    EGR tube
     
    Spark plugs and ignition coils
     
    Coolant hoses
     
    Canister purge hoses
     
    Fuel feed and return lines
     
    Vacuum hoses
     
    Negative battery cable
     

  34.  
  35. Fill the cooling system.
  36.  
  37. Fill the engine with clean oil.
  38.  
  39. Start the vehicle, check for leaks and repair if necessary.
  40.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the timing chain case, camshaft sprockets, timing chain and rear timing chain case.
  12.  
  13. Remove or disconnect the following:

    Camshaft position sensors (PHASE) from the back of the cylinder heads
     
    Intake valve timing control solenoid valves and discard the gaskets
     
    Camshaft bearing caps in the reverse of the tightening sequence
     
    Camshafts
     
    Valve lifters
     
    Secondary timing chain tensioners

    Click image to see an enlarged view

    Fig. Exploded view of camshaft assemblies-350Z 3.5L engine



    Click image to see an enlarged view

    Fig. Camshaft bearing cap tightening sequence-350Z 3.5L engine

     

  14.  

To install:


NOTE
Before installing the camshaft brackets, apply RTV sealant to the mating surface of the No. 1 journal head.

  1. Lubricate the valve lifters with clean engine oil and install the lifters into the bore from which they were removed.
  2.  
  3. Lubricate the valve lifter shims with clean engine oil and install the shims into the lifter from which they were removed.
  4.  
  5. Ensure the crankshaft is set to TDC for the No. 1 cylinder.
  6.  
  7. Install the camshaft tensioners using new O-rings on both sides of the cylinder heads. The sliding part faces downward on the right head and upward on the left head. Torque the bolts to 75 inch lbs. (8.4 Nm).
    NOTE
    The camshafts can be identified by the paint marks on the camshaft. The intake camshafts have a PINK paint mark and the exhaust camshafts have a ORANGE paint mark.



    Install the camshafts so the large and small pin holes are located on the front face of the camshafts at 180° intervals.

    Click image to see an enlarged view

    Fig. Camshaft dowel pin installation location-350Z 3.5L engine

     
    Camshaft bearing cap stamp positioning-350Z 3.5L engine

    Click image to see an enlarged view

    Fig.

     

  8.  
  9. Install the bearing caps aligning the stamp marks on the caps as shown.
  10.  
  11. Torque the camshaft bearing caps as follows:
    1. Bolts No. 7-10: 17 inch lbs. (2 Nm).
    2.  
    3. Bolts No. 1-6: 17 inch lbs. (2 Nm).
    4.  
    5. Bolts No. 1-10: 52 inch lbs. (6 Nm).
    6.  
    7. Bolts No. 1-6: 81-104 inch lbs. (9-11 Nm).
    8.  
    9. Bolts No. 7-10: 74-91 inch lbs. (8.3-10.3 Nm).
    10.  

  12.  
  13. Check and adjust the valve clearance.
  14.  
  15. Install or connect the following:

    Intake valve timing control solenoid valves using new gaskets and tighten the bolts to 8 ft. lbs. (11.3 Nm)
     
    Camshaft position sensors (PHASE) and tighten the bolts to 85 inch lbs. (9.6 Nm)
     
    Timing chain case, camshaft sprockets, timing chain and rear timing chain case
     
    Negative battery cable
     

  16.  
  17. Fill the cooling system.
  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Start the vehicle, check for leaks and repair if necessary.
  22.  

1.6L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.

    Click image to see an enlarged view

    Fig. Be sure to install the camshaft bearing caps in their original positions-1.6L engine

  6.  
  7. Remove or disconnect the following:
    NOTE
    Before the camshafts are removed from the cylinder head, note the positioning of the pins at the end of the camshafts for reassembly purposes.



    Negative battery cable
     
    All engine drive belts
     
    Exhaust pipe from the exhaust manifold
     
    Power steering pulley and pump with the mounting bracket
     
    Cylinder head cover
     
    Distributor assembly
     
    Timing chain tensioners and camshaft sprocket
     



    Camshaft bearing caps in sequence
     
    Camshafts from the cylinder head
     
    Idler sprocket bolt. These parts should be reassembled in their original position.
     
    Shims from the tops of the lifters. Be sure to note the position of each shim.
     
    Valve lifters from the bores in the cylinder head. Note the positioning of the lifters for reassembly.
     

  8.  
  9. Measure the diameter of the lifters. The diameter should be 1.1795-1.1801 in. (29.960-29.975mm).
  10.  
  11. Measure the diameter of the lifter bores. The diameter should be 1.1811-1.1819 in. (30.000-30.021mm).
  12.  
  13. Clearance between the lifter and bore should be 0.0010-0.0024 in. (0.025-0.061mm).
  14.  

To install:

  1. Install or connect the following:
    NOTE
    The exhaust and intake camshafts are marked with identification stamps. (E for exhaust and I for intake).



    Lifters and shims to the cylinder head in the proper locations as noted during removal
     



    Camshafts to the cylinder head and position the intake camshaft knock pin at the 9 o'clock position and the exhaust camshaft at the 12 o'clock position

    Click image to see an enlarged view

    Fig. Positioning and identification of the camshafts-1.6L engine



    Click image to see an enlarged view

    Fig. If removed, apply liquid gasket to the distributor bracket as shown-1.6L engine



    Click image to see an enlarged view

    Fig. Camshaft bolt torque sequence-1.6L engine

     

  2.  
  3. Install the camshaft bearing caps and tighten the mounting bolts as follows:
    1. Bolts 11 through 15, then bolts 1 through 10: 18 inch lbs. (2 Nm).
    2.  
    3. Bolts 1 through 15: 53 inch lbs. (6 Nm).
    4.  
    5. Bolts 1 through 14: 87-105 inch lbs. (10-12 Nm).
    6.  
    7. Bolt 15: 56-73 inch lbs. (7-8 Nm).
      NOTE
      If any part of the valvetrain has been has been replaced, the valve adjustment must be checked. DO NOT adjust the valves or rotate the camshafts at this point. Internal engine damage will result.

    8.  

  4.  
  5. Install or connect the following:

    Camshaft sprockets with timing chains
     
    Distributor assembly
     

  6.  
  7. Check and adjust the valve clearance.
  8.  
  9. Install or connect the following:

    Cylinder head cover
     
    Power steering pulley pump
     
    Exhaust pipe from the exhaust manifold
     
    All engine drive belts
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    All engine drive belts
     
    Exhaust pipe from the exhaust manifold
     
    Power steering pulley and pump with the mounting bracket
     
    Cylinder head cover
     
    Distributor assembly
     
    Timing chain tensioners and camshaft sprocket
     

  8.  


    Click image to see an enlarged view

    Fig. Be sure to install the camshaft bearing caps in their original positions-1.8L engine



NOTE
Before the camshafts are removed from the cylinder head, note the positioning of the pins at the end of the camshafts for reassembly purposes.



Camshaft bearing caps in sequence
 
Camshafts from the cylinder head
 
Idler sprocket bolt. These parts should be reassembled in their original position.
 
Shims from the tops of the lifters. Be sure to note the position of each shim.
 
Valve lifters from the bores in the cylinder head. Note the positioning of the lifters for reassembly.
 

  1. Measure the diameter of the lifters. The diameter should be 1.1795-1.1801 in. (29.960-29.975mm).
  2.  
  3. Measure the diameter of the lifter bores. The diameter should be 1.1811-1.1819 in. (30.000-30.021mm).
  4.  
  5. Clearance between the lifter and bore should be 0.0010-0.0024 in. (0.025-0.061mm).
  6.  

To install:

  1. Install or connect the following:

    Lifters and shims to the cylinder head in the proper locations as noted during removal
     

  2.  


NOTE
The exhaust and intake camshafts are marked with identification stamps. (E for exhaust and I for intake).



Camshafts to the cylinder head and position the intake camshaft knock pin at the 9 o'clock position and the exhaust camshaft at the 12 o'clock position
 



Click image to see an enlarged view

Fig. Positioning and identification of the camshafts-1.8L engine



Click image to see an enlarged view

Fig. If removed, apply liquid gasket to the distributor bracket as shown-1.8L engine



Click image to see an enlarged view

Fig. Camshaft bolt torque sequence-1.8L engine

  1. Install the camshaft bearing caps and tighten the mounting bolts as follows:
    1. Bolts 11 through 15, then bolts 1 through 10: 18 inch lbs. (2 Nm).
    2.  
    3. Bolts 1 through 15: 53 inch lbs. (6 Nm).
    4.  
    5. Bolts 1 through 14: 87-105 inch lbs. (10-12 Nm).
    6.  
    7. Bolt 15: 56-73 inch lbs. (7-8 Nm).
    8.  

  2.  


NOTE
If any part of the valvetrain has been has been replaced, the valve adjustment must be checked. DO NOT adjust the valves or rotate the camshafts at this point. Internal engine damage will result.

  1. Install or connect the following:

    Camshaft sprockets with timing chains
     
    Distributor assembly
     

  2.  
  3. Check and adjust the valve clearance.

    Cylinder head cover
     
    Power steering pulley pump
     
    Exhaust pipe from the exhaust manifold
     
    All engine drive belts
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

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

    Negative battery cable
     
    Rocker cover and oil separator
     

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

    Timing chain tensioner
     
    Distributor
     
    Timing chain guide
     
    Camshaft sprockets. Use a wrench to hold the camshaft while loosening the sprocket bolt.
     
    Camshaft bracket bolts in the opposite order of the tightening sequence
     
    Camshaft
     

  8.  

To install:



Click image to see an enlarged view

Fig. To prevent damage to the camshafts, torque the bearing caps in the numbered.



Click image to see an enlarged view

Fig. and lettered sequence shown. Refer to the text for the proper torque-2.0L engines

  1. Clean the left-hand camshaft end bracket and coat the mating surface with liquid gasket. Install the camshafts, camshaft brackets, oil tubes and baffle plate. Ensure the left camshaft key is at 12 o'clock and the right camshaft key is at 10 o'clock.
  2.  
  3. The procedure for tightening camshaft bolts must be followed exactly to prevent camshaft damage. Torque the bolts as follows:
    1. Right bolts 9 and 10 (in that order): 18 inch lbs. (2 Nm).
    2.  
    3. Right bolts 1-8 (in that order): 18 inch lbs. (2 Nm).
    4.  
    5. Left bolts 11 and 12 (in that order): 18 inch lbs. (2 Nm).
    6.  
    7. Left bolts 1-10 (in that order): 18 inch lbs. (2 Nm).
    8.  
    9. All bolts in sequence: 52 inch lbs. (6 Nm).
    10.  
    11. All bolts in sequence: 7-9 ft. lbs. (9-12 Nm) for type A, B and C bolts and 13-19 ft. lbs. (18-25 Nm) for type D bolts.
    12.  

  4.  
  5. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Torque the sprocket bolts to 101-116 ft. lbs. (137-157 Nm).
  6.  
  7. Install or connect the following:

    Timing chain guide
     
    Distributor
     
    Timing chain tensioner
     
    Rocker cover and oil separator
     
    Negative battery cable
     

  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain coolant from the engine and radiator.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake ducts and the air cleaner assembly
     
    Vacuum hoses, fuel hoses, wires, harness and connectors that are necessary for removal of the rocker cover
     
    Alternator and mounting bracket
     
    Upper radiator hose and cooling fan
     

  8.  
  9. Set the No. 1 piston at Top Dead Center (TDC) on its compression stroke.

    Spark plug wires from the spark plugs
     
    Distributor assembly. Matchmark and note the positioning of the distributor rotor and housing to the engine block before removing the distributor.
     
    Rocker cover by loosening the bolts in the reverse order of installation
     

  10.  
  11. Wire the chain to the sprocket so the chain does not fall off during sprocket removal. Hold the flats of the camshaft with a wrench just behind the first camshaft bearing cap. Loosen the bolts and remove the sprockets.

    Camshaft sprockets
     

  12.  


NOTE
The stoppers on camshaft covers prevent the upper timing chain from disengaging from the idle sprocket. Also, after removal of the camshaft sprockets, note the positioning of the pins at the end of the camshafts for reinstallation purposes.



Camshaft bearing caps in reverse order of installation
 
Camshafts. The camshaft brackets must be loosened in the correct sequence to prevent damage to the camshaft.
 


NOTE
All the valvetrain components must be reassembled in their original positions.



Valve lifter adjusting shims from the tops of the of the lifters. Be sure to note the location and positioning of each shim.
 
Valve lifters from the bores in the cylinder heads. Be sure to note the location and positioning of each lifter.
 

  1. Check the diameter of the valve lifter and the valve lifter bore and compare to the following specifications.
  2.  
  3. The valve lifter diameter should be 1.3370-1.3376 in. (33.960-33.975mm).
  4.  
  5. The lifter guide bore diameter should be 1.3386-1.3394 in. (33.960-33.975mm).
  6.  
  7. The valve lifter to lifter guide bore clearance should be 0.0010-0.0024 in. (0.025-0.061mm).
  8.  

To install:


NOTE
When installing the valve components, apply a coat of clean engine oil to the component.

  1. Install or connect the following:

    Lifters into the lifter bores from which they were removed
     
    Valve shims to the lifters from which they came
     

  2.  
  3. Install the camshafts in the same position as noted during removal and camshaft bearing caps; torque cap bolts in the proper sequence as follows:
    1. Step 1: 17 inch lbs. (2 Nm).
    2.  
    3. Step 2: 81-104 inch lbs. (9-12 Nm).
    4.  

  4.  


NOTE
When installing the timing chain and sprockets, align the marks on the sprockets with the colored links of the chain.

  1. Install or connect the following:

    Camshaft sprockets with the timing chain and torque the bolts to 123-130 ft. lbs. (167-177 Nm). Install the chain guide between both camshaft sprockets. The alignment marks on the upper portion of the timing chain should now be aligned with the marks on the sprockets.
     
    Rocker cover
     
    Distributor
     
    Spark plugs and wires
     
    Upper radiator hose and cooling fan
     
    Alternator
     
    Vacuum hoses, fuel lines and electrical connectors
     
    Air cleaner assembly
     
    Negative battery cable
     

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


    Click image to see an enlarged view

    Fig. Tighten the camshaft bearing caps in sequence to prevent damage to the camshaft and cylinder head-2.4L engines


2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain coolant from the engine and radiator.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     
    Right front wheel
     
    Valve cover
     
    Drive belt
     
    Coolant reservoir
     
    Variable timing control solenoid connector
     
    Camshaft position sensor
     
    Intake valve timing control cover in reverse of the tightening sequence
     
    Set the No. 1 piston at Top Dead Center (TDC) on its compression stroke
     

  8.  
  9. Check that the mating marks on the camshaft sprockets are lined up with the Yellow links on the timing chain. If not, rotate the crankshaft one revolution until the links line up.
  10.  
  11. Remove the timing chain guide out between the camshaft sprockets through the front cover.
  12.  
  13. Push in the plunger on the timing chain tensioner, then insert a pin to hold the tensioner retracted.
  14.  
  15. Remove the timing chain tensioner .
  16.  
  17. While holding the flat of the camshaft with an open end wrench, loosen and remove the camshaft sprockets.
  18.  
  19. Loosen the camshaft brackets in the order shown .
  20.  
  21. Remove the camshafts.
  22.  
  23. Remove the valve lifters.
  24.  


    Click image to see an enlarged view

    Fig. Camshaft bearing cap removal sequence-2.5L engines



    Click image to see an enlarged view

    Fig. Identifiying camshaft bearing cap installation marks-2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft bearing cap tightening sequence-2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft sprocket alignment marks-2.5L engines



    Click image to see an enlarged view

    Fig. Intake valve timing cover tightening sequence-2.5L engines


To install:


NOTE
When installing the valve components, apply a coat of clean engine oil to the component.

  1. Install or connect the following:

    Lifters into the lifter bores from which they were removed
     
    Valve shims to the lifters from which they came
     

  2.  
  3. Install the camshafts so the dowel pin on the intake camshaft is placed at the three o-clock position and the exhaust camshaft pin is placed at the twelve o-clock position.
  4.  
  5. Install the camshaft caps with the identifying marks placed in the correct position as shown.
  6.  
  7. Place a bead of sealant of the No. 1 bearing cap bottom edge.
  8.  
  9. Place a bead of sealant on the back side of the front cover where the No. 1 bearing cap lines up.
  10.  
  11. Apply sealant to the bolt hole on the front cover.
  12.  
  13. Install the No. 1 bearing cap so the sealant joints line up.
  14.  
  15. Tighten the camshaft bearing caps bolts in the proper sequence as follows:
    1. Step 1 bolts 9-11: 17 inch lbs. (2 Nm).
    2.  
    3. Step 2 bolts 1-8: 17 inch lbs. (2 Nm).
    4.  
    5. Step 3 bolts 1-11: 52 inch lbs. (6 Nm).
    6.  
    7. Step 4 bolts 1-11: 80-104 inch lbs. (9-12 Nm).
    8.  

  16.  
  17. Install the camshaft sprockets so the mating marks are aligned as shown.
  18.  
  19. Install or connect the following:

    Timing chain tensioner and remove the pin
     
    Intake valve timing control cover and tighten the bolts in the sequence shown.
     
    Check and adjust the valve clearance as necessary.
     
    Timing chain guide between the camshaft sprockets through the front cover
     
    Camshaft position sensor
     
    Variable timing control solenoid connector
     
    Coolant reservoir
     
    Drive belt
     
    Valve cover
     
    Right front wheel
     
    Negative battery cable
     
    Engine undercover
     

  20.  
  21. Fill the cooling system.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

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

    Negative battery cable
     
    Left side rocker cover ornament
     

  10.  


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



Air duct to intake manifold hose, collector hose, blow-by hose and vacuum hoses
 
Fuel hoses and detach the harness connections
 
Canister purge hoses
 
Water hoses from the cylinder head and intake manifold
 
All 6 ignition coils from the spark plugs
 
Spark plugs
 
Bolts that secure the Exhaust Gas Recirculation (EGR) tube
 
EGR tube
 
Intake manifold collector supports and the collector
 
Bolts that secure the fuel tube and the fuel tube
 
Bolts that secure the intake manifold to the engine block and the manifold. Loosen the bolts in the reverse sequence of the tightening procedure.
 
Left-hand and right-hand rocker covers from the cylinder head
 
Engine undercovers
 
Right front wheel and engine side covers
 
Drive belts and idler pulley
 
Power steering oil pump belt and the power steering oil pump assembly
 
Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS)
 

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

    Ring gear cover access plate. Loosen the crankshaft pulley bolt while securing the ring gear so the crankshaft cannot rotate
     
    Crankshaft pulley, using a suitable puller
     
    Air conditioning compressor and bracket
     
    Front exhaust pipe and its support
     

  2.  
  3. Hang the engine at the right and left side engine slingers with a suitable hoist.
  4.  
  5. Support the transaxle with jack.

    Right side engine mounting, mounting bracket and nuts
     
    Center crossmember assembly
     
    Steel (lower) oil pan bolts in the reverse of the installation sequence
     

  6.  
  7. Insert a seal cutter between the steel and aluminum oil pan
  8.  
  9. Tapping the cutter with a hammer, slide it around the entire edge of the oil pan. Be careful not to damage the aluminum mating surface of the upper oil pan.

    Steel oil pan and the oil strainer
     
    Aluminum (upper) oil pan bolts in the reverse of the installation sequence
     
    Transaxle bolts that secure the oil pan
     

  10.  
  11. Insert a seal cutter between the aluminum oil pan and the engine block.
  12.  
  13. Tapping the cutter with a hammer, slide it around the entire edge of the oil pan. Be careful not to damage the mating surfaces of the oil pan or engine block.

    Oil pan from the vehicle
     
    Water pump cover and the bolts that secure the front timing chain case cover
     
    Timing chain case cover, using the seal cutter
     
    Internal timing chain guide and the upper chain guide
     
    Timing chain tensioner and slack side chain guide
     
    Left and right intake camshaft sprockets first. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
     
    Lower timing chain assembly. Be sure to note the aligning marks of the chain before removal.
     

  14.  
  15. Insert a suitable stopper pin for the left and right camshaft tensioners.

    Left and right exhaust camshaft sprocket bolts. Be sure to hold the flats of the camshafts while removing the sprocket bolts.
     
    Upper timing chain assembly. Be sure to note the aligning marks of the chain before removal.
     
    Lower timing chain guide
     
    Crankshaft sprocket
     
    Bolts that secure the rear timing chain case. The bolts must be loosened in sequence.
     
    Rear timing case cover, using the seal cutter
     

  16.  


NOTE
Remove the O-rings from the front of the engine block.



Camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence.
 


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



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


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



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

  1. Check the diameter of the valve lifter and the valve lifter guide bore.
  2.  
  3. The diameter of the lifter should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021mm).
  4.  
  5. Remove all traces of liquid gasket from the timing chain case and from the water pump covers.
  6.  
  7. Remove all traces of liquid gasket from the engine block.
  8.  
  9. Inspect the camshafts for excessive wear or damage and replace as necessary.
  10.  

To install:



Click image to see an enlarged view

Fig. Camshaft identification marks-3.0L and 3.5L engines


NOTE
Before installing the camshaft brackets, apply RTV sealant to the mating surface of the No. 1 journal head.

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

    Camshaft tensioners on both sides of the cylinder heads and torque the bolts to 75-96 inch lbs. (8.4-10.8 Nm)
     

  8.  


NOTE
The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylinder head camshafts have a WHITE paint mark.



Click image to see an enlarged view

Fig. Right cylinder head camshaft bearing cap tightening sequence-3.0L and 3.5L engines



Click image to see an enlarged view

Fig. Left cylinder head camshaft bearing cap tightening sequence-3.0L and 3.5L engines



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


NOTE
When installing the camshafts, position the camshaft keys at the 12 o'clock position in respect to the cylinder head angle.

  1. Torque the camshaft bearing caps as follows:
    1. Bolts No. 7-10: 17 inch lbs. (2 Nm).
    2.  
    3. Bolts No. 1-6: 17 inch lbs. (2 Nm).
    4.  
    5. Bolts No. 1-10: 52 inch lbs. (6 Nm).
    6.  
    7. Bolts No. 1-10: 81-104 inch lbs. (9-11 Nm).
    8.  

  2.  
  3. Install new O-rings to the front of the engine block.
  4.  
  5. Apply sealant to the hatched portion of the of the rear timing chain case.
  6.  
  7. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block.
  8.  
  9. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm).
  10.  
  11. Install the crankshaft sprocket with the mating mark facing out.
  12.  
  13. Rotate the crankshaft clockwise and position the crankshaft to TDC of compression stroke and align the dowels of the camshaft sprockets to the 12 o'clock position in respect to the cylinder head.
  14.  
  15. Install the lower chain guide on the dowel pin with the front mark on the guide facing upward.
  16.  
  17. On a workbench, align the marks on the intake and exhaust camshaft sprockets with the marks of the chain.
  18.  
  19. Put the exhaust camshaft sprockets onto the dowel pin and torque the bolts to 88-95 ft. lbs. (119-128 Nm). Be sure to secure the camshafts while tightening the bolts.
  20.  
  21. Install or connect the following:

    Timing chains, sprockets and related components
     
    Transaxle bolts that secure the oil pan
     
    Oil pan strainer and torque the bolts to 12-14 ft. lbs. (16-19 Nm)
     

  22.  
  23. Apply a 0.177-0.217 in. (4.5-5.5mm) continuous bead of liquid gasket to the lower oil pan mating surface and install the oil pan. Torque the bolts in sequence to 57-66 inch lbs. (6.4-7.5 Nm).

    Center crossmember assembly
     
    Right side engine mounting bracket and mount assembly
     

  24.  
  25. Remove the engine slinger assembly.

    Front exhaust pipe and its support
     
    Air conditioning compressor and bracket
     
    Crankshaft pulley to the crankshaft and install the mounting bolt. Torque the bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66 degrees clockwise. This is about the angle from one hexagon bolt head corner to another
     
    CMP sensor, PHASE and CKP sensors
     
    Power steering pump
     
    Idler pulley and all belts
     
    Engine side and under covers
     
    Right front wheel
     
    Intake manifold
     
    Rocker covers
     
    Fuel tube
     
    Intake manifold support and collector
     
    EGR tube
     
    Spark plugs and ignition coils
     
    Coolant hoses
     
    Canister purge hoses
     
    Fuel feed and return lines
     
    Vacuum hoses
     
    Negative battery cable
     

  26.  
  27. Fill the cooling system.
  28.  
  29. Fill the engine with clean oil.
  30.  
  31. Start the vehicle, check for leaks and repair if necessary.
  32.  

 
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