REMOVAL & INSTALLATION
- Remove the engine assembly from the vehicle as previously described in the Engine removal procedures in this section.
- Install the engine on a support stand.
- Remove the rocker arm cover, loosen the valve rocker arm bolts and swing the rocker arms clear of the pushrods.
- Remove the distributor (non DIS system).
- Remove the pushrod cover, pushrods and valve lifters.
- Remove the alternator, lower alternator bracket and front engine mount bracket assembly.
- Remove the oil pump driveshaft and gear assembly.
- Remove the front pulley hub and timing gear cover as outlined in the Timing Gear Cover removal procedures in this section.
- Remove the two camshaft thrust plate screws by working through the holes in the camshaft gear. Refer to the Thrust Plate illustration in this section.
- Remove the camshaft and gear assembly by pulling it out through the front of the block.
Support the shaft carefully when removing so as not to damage the camshaft bearings.
- If the gear must be removed from the shaft, use the press plate and adapter J-971 on the press.
- Place the tools on the table of the press. Place the camshaft through the openings in the tools, then press the shaft out of the gear using a socket or other suitable tool. Refer to the Camshaft Gear removal illustration in this section.
The thrust plate must be so positioned that the Woodruff key in the shaft does not damage it when the shaft is pressed out of the gear.
- To assemble the camshaft gear, thrust plate and gear spacer ring to the camshaft, proceed as follows:
- Firmly support the shaft at the back of the front journal in an arbor press using press plate adapters.
- Place the gear spacer ring and thrust plate over the end of the shaft, and install a Woodruff key in the shaft keyway.
- Install the camshaft gear and press it onto the shaft until it bottoms against the gear spacer ring. The end clearance of the thrust plate should be 0.025-0.130mm. If less than 0.04mm, the thrust plate should be replaced.
- Thoroughly coat the camshaft journals with a high quality Assembly Lube or engine oil supplement.
- Install the camshaft assembly into the engine, being careful not to damage the bearings or cam.
- Turn the crankshaft and camshaft so that the valve timing marks on the gear teeth will line up. The engine is now in the No. 4 firing position. Install the camshaft thrust plate-to-block screws and tighten to 90 inch lbs. (10 Nm).
- Install the timing gear cover and gasket as outlined in the Timing Gear Cover installation procedures in this section.
- Line up the keyway in the hub with the key on the crankshaft and slide the hub onto the shaft. Install the center bolt and torque to 162 ft. lbs. (220 Nm).
- Coat each valve lifter with Assembly Lube® Install the valve lifters, pushrods, pushrod cover, oil pump shaft and gear assembly and fuel pump as previously described.
- Install the distributor (non DIS system) as follows:
- Turn the crankshaft 360° to the firing position of the No. 1 cylinder (number 1 exhaust and intake valve lifters both on base circle of camshaft and timing mark on the harmonic balancer indexed with the TDC mark on the timing pad).
- Install the distributor in its original position and align the shaft so the rotor arm points toward the No. 1 cylinder spark plug contact.
- Swing the rocker arms over the pushrods. With the lifters on the base circle of the camshaft, tighten the rocker arm bolt to 24 ft. lbs. (32 Nm). Do not over torque.
- Install the front mount assembly, lower alternator bracket and alternator.
- Install the engine assembly into the vehicle as outlined in the Engine installation procedures in this section.