Toyota Tundra 2001-06

Camshaft, Bearings & Lifters 1

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Inspection



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the camshaft from the engine.
  4.  
  5. Check the camshaft bearing journals for damage and binding.
  6.  
  7. If the journals are binding, check the cylinder head for damage.
  8.  
  9. Check the cylinder head for clogged oil holes.
  10.  
  11. Check the camshaft surface for abnormal wear and damage. Replace the camshaft, as required.
  12.  
  13. Measure the camshaft lobe surface and replace the camshaft if not within specification.
  14.  
  15. Measure the camshaft journal diameter and replace the camshaft if not within specification.
  16.  
  17. Measure the camshaft run out and replace the camshaft if not within specification.
  18.  

Removal & Installation



1gr-FE Engine
Bank 1
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly disarm the SRS system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant. Remove the V bank cover.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Disconnect the two water bypass hoses. Disconnect the fuel vapor feed hose. Disconnect the ventilation hose. Disconnect the VSV connectors.
  12.  
  13. Disconnect the throttle body motor connector. Separate the three wire harness clamps and hose clamp.
  14.  
  15. Remove the two bolts and the throttle body bracket. Remove the bolt and the oil baffle plate. Remove the four bolts and the two serge tank stays.
  16.  
  17. Remove the two nuts. Remove the four bolts, intake air surge tank and gasket.

    Click image to see an enlarged view

    Fig. Intake surge tank bolt locations-4.0L engine

  18.  
  19. Remove the ignition coil assembly.
  20.  
  21. Remove the cylinder head cover retaining bolts. Remove the cylinder head cover.
  22.  
  23. Turn the crankshaft pulley until its groove and the timing mark -0- of the timing chain cover are aligned. If not aligned at TDC of the compression stroke, turn the crankshaft one complete revolution, in the direction of rotation. Paint alignment marks on the number one chain links corresponding to the timing marks of the camshaft timing gears.

    Click image to see an enlarged view

    Fig. Bank 1 camshaft timing mark alignment-4.0L engine

  24.  
  25. Remove the four bolts, and then remove the timing chain cover plate and gasket.
  26.  
  27. While turning the stopper plate of the tensioner upward, push the plunger of the chain tensioner. While turning the stopper plate of the tensioner downward, insert a 0.118 inch diameter bar into the holes in the stopper plate and tensioner to hold the stopper plate.
  28.  
  29. Remove the two bolts, and then remove the chain tensioner.
    NOTE
    Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. Follow the steps below to prevent this problem from occurring.

  30.  
  31. While raising the chain tensioner number two insert a 0.039 inch diameter pin into the hole to hold it. Hold the hexagonal portion of the number two camshaft with a wrench. Remove the camshaft timing gear set bolt.
  32.  
  33. Separate the camshaft timing gear from the number two camshaft. Rotate the camshafts counterclockwise, using a wrench, so that the cam lobes of the number one cylinder face in the direction shown.

    Click image to see an enlarged view

    Fig. Bank 1 camshaft lobe removal positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 camshaft number two bearing cap bolt removal sequence-4.0L engine

  34.  
  35. Using several steps, loosen and remove the eight bearing cap bolts uniformly and in the proper removal sequence. Remove the four bearing caps and the number two camshaft.
  36.  
  37. Remove the number two chain tensioner bolt. Remove the number chain tensioner and camshaft timing gear.
    NOTE
    Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. Follow the steps below to prevent this problem from occurring.

  38.  
  39. Hold the hexagonal portion of the number one camshaft, with a wrench. Loosen the camshaft timing gear set bolt.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  40.  
  41. Slide the camshaft timing gear and separate the number one chain from the camshaft timing gear.
  42.  
  43. Rotate the number one camshaft counterclockwise, using the wrench so that the cam lobes on the number one cylinder face downward.
  44.  
  45. Using several steps, loosen and remove the eight bearing cap bolts uniformly and in the proper removal sequence. Remove the four bearing caps.

    Click image to see an enlarged view

    Fig. Bank 1 camshaft number one bearing cap bolt removal sequence-4.0L engine

  46.  
  47. Remove the camshaft timing gear set bolt with the number one camshaft lifted up. Remove the number one camshaft and camshaft timing gear with the number two chain.
  48.  
  49. Tie the number one chain to the side. Be careful not to drop anything inside the timing chain cover.
  50.  

To install:


NOTE
Keep the camshaft level while it is being installed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust.

  1. Align the yellow mark link with the timing mark (1 dot mark) of the camshaft timing gear. Apply new engine oil to the thrust portion and journal of the camshafts.

    Click image to see an enlarged view

    Fig. Bank 1 camshaft number one alignment marks-4.0L engine

  2.  
  3. Temporarily install the number one chain onto the number two chain of the camshaft timing gear.
  4.  
  5. Align the knock pin hole of the camshaft timing gear with the knock pin of the number one camshaft. Insert the number one camshaft into the camshaft timing gear.
  6.  
  7. Temporarily install the camshaft timing gear set bolt. Install the number one camshaft onto the right cylinder head with the cam lobes of the number one cylinder facing downward, as indicated in the illustration.

    Click image to see an enlarged view

    Fig. Bank 1 camshaft number one lobe installation positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 camshaft number one bearing cap bolt installation sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 camshaft number one bearing cap bolt torque sequence-4.0L engine

  8.  
  9. Install the four bearing caps, in the proper location. Apply a light coat of engine oil to the threads and under the heads of the cap bolts.
  10.  
  11. Using several steps, uniformly install and tighten the bearing cap bolts in the proper sequence to 80 inch lbs. for the 10mm bolts and 18 ft. lbs. for the 12mm bolts.
  12.  
  13. Rotate the number one camshaft clockwise, using a wrench so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap.
  14.  
  15. Align the paint mark of the number one chain with the timing mark of the camshaft timing gear.
  16.  
  17. Hold the hexagonal portion of the number one camshaft with a wrench, and tighten the camshaft timing gear set bolt to 74 ft. lbs.
  18.  
  19. While pushing in on the number two chain tensioner, insert a 0.039 inch pin into the hole to hold it.
  20.  
  21. Temporarily install the camshaft timing gear and chain tensioner number two and align the yellow mark links with the timing marks (1 dot mark) on the camshaft timing gears. Tighten the bolt to 14 ft. lbs.
    NOTE
    Keep the camshaft level while it is being installed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust.



    Click image to see an enlarged view

    Fig. Bank 1 camshaft number two alignment marks-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 camshaft number two lobe installation positioning-4.0L engine

  22.  
  23. Install the number two camshaft onto the right cylinder head with the cam lobes of the number one cylinder facing upward, as indicated in the illustration.
  24.  
  25. Install the four bearing caps in the proper location. Apply a light coat of clean engine oil to the threads and under the heads of the bolts.
  26.  
  27. Using several steps, uniformly install and tighten the eight bearing cap bolts in sequence to 80 inch lbs, for the 10mm head bolts and 18 ft. lbs. for the 12mm head bolts.

    Click image to see an enlarged view

    Fig. Bank 1 camshaft number two bearing cap bolt installation sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 1 camshaft number two bearing cap bolt torque sequence-4.0L engine

  28.  
  29. Rotate the number two camshaft clockwise, using a wrench, so that the lock pin of the number two camshaft is aligned with the knock pin hole of the camshaft timing gear.
  30.  
  31. Hold the hexagonal portion of the number two camshaft, with a wrench, and install the camshaft timing gear set bolt and tighten it to 74 ft. lbs.
  32.  
  33. Remove the pin from the number two chain tensioner.
  34.  
  35. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner. While turning the stopper plate of the tensioner counterclockwise, insert a 0.138 inch bar into the holes in the stopper plate and tensioner to hold the stopper plate. Install the two chain tensioner bolts and tighten to 7.4 ft. lbs.
  36.  
  37. Remove the bar from the chain tensioner. Install a new gasket and the timing chain cover plate. Torque the bolts to 80 inch lbs.
  38.  
  39. Turn the crankshaft pulley two complete revolutions slowly until its groove and the timing mark -0- of the timing chain cover are aligned.

    Click image to see an enlarged view

    Fig. Bank 1 and Bank 2 timing mark alignment-4.0L engine

  40.  
  41. Position the number one cylinder at TDC of the compression stroke. Inspect the valve clearance, adjust as required.
  42.  
  43. Apply a continuous bead (0.08-0.12 inch) of seal packing, part number 08826-00080 or equivalent, to the cylinder head as indicated in the illustration. Install the seal washers onto the bolts. Install the cylinder head cover bolts and nuts. Tighten bolts -A- to 7.4 ft. lbs. Tighten bolts -B- to 80 inch lbs. Tighten nuts to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Tighten the bolts to specification within fifteen minutes after installing the cover. Do not add engine oil for at least two hours after installing the cover.



    Click image to see an enlarged view

    Fig. Bank 1 cylinder head cover bolt sealant application and bolt identification-4.0L engine

  44.  
  45. Continue the installation in the reverse order of the removal procedure.
  46.  
  47. Be sure to fill the engine with the proper grade and type engine coolant.
  48.  
  49. Be sure to fill the engine with the proper grade and type engine oil.
  50.  
  51. Start the engine and check for leaks. Correct as required.
  52.  

Bank 2
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly disarm the SRS system.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the engine coolant. Remove the V bank cover.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Disconnect the two water bypass hoses. Disconnect the fuel vapor feed hose. Disconnect the ventilation hose. Disconnect the VSV connectors.
  12.  
  13. Disconnect the throttle body motor connector. Separate the three wire harness clamps and hose clamp.
  14.  
  15. Remove the two bolts and the throttle body bracket. Remove the bolt and the oil baffle plate. Remove the four bolts and the two serge tank stays.
  16.  
  17. Remove the two nuts. Remove the four bolts, intake air surge tank and gasket.
  18.  
  19. Remove the ignition coil assembly.
  20.  
  21. Remove the cylinder head cover retaining bolts. Remove the cylinder head cover.
  22.  
  23. Turn the crankshaft pulley until its groove and the timing mark -0- of the timing chain cover are aligned. If not aligned at TDC of the compression stroke, turn the crankshaft one complete revolution, in the direction of rotation. Paint alignment marks on the number one chain links corresponding to the timing marks of the camshaft timing gears.
  24.  
  25. While turning the stopper plate of the tensioner upward, push in the plunger of the chain tensioner. While turning the stopper plate of the tensioner downward, insert a 0.138 inch bar into the holes in the stopper plate and tensioner to hold the stopper plate. Remove the two bolts and then remove the number one chain tensioner assembly.
    NOTE
    Never rotate the crankshaft with the chain tensioner removed. When rotating the camshaft with the tensioner removed, rotate the crankshaft counterclockwise forty degrees from TDC, first.


    NOTE
    Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. Follow the steps below to prevent this problem from occurring.

  26.  
  27. While pushing down on chain tensioner number three insert a 0.039 inch diameter pin into the hole to hold it. Hold the hexagonal portion of the number four camshaft with a wrench. Remove the camshaft timing gear set bolt.
  28.  
  29. Separate the camshaft timing gear from the number four camshaft.

    Click image to see an enlarged view

    Fig. Bank 2 camshaft number four bearing cap bolt removal sequence-4.0L engine

  30.  
  31. Using several steps, loosen and remove the eight bearing cap bolts uniformly and in the proper removal sequence. Remove the four bearing caps and the number four camshaft.
  32.  
  33. Remove the number three chain tensioner bolt. Remove the number chain tensioner and camshaft timing gear.
    NOTE
    Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. Follow the steps below to prevent this problem from occurring.

  34.  
  35. Release the chain tension between the camshaft gear (LH bank) and the crankshaft timing gear by turning the crankshaft pulley counterclockwise slightly.
  36.  
  37. Hold the hexagonal portion of the number three camshaft, with a wrench. Loosen the camshaft timing gear set bolt.
    NOTE
    Do not disassemble the camshaft timing gear assembly.

  38.  
  39. Slide the camshaft timing gear and separate the number one chain from the camshaft timing gear.
  40.  
  41. Using several steps, loosen and remove the eight bearing cap bolts uniformly and in the proper removal sequence. Remove the four bearing caps.

    Click image to see an enlarged view

    Fig. Bank 2 camshaft number three bearing cap bolt removal sequence-4.0L engine

  42.  
  43. Remove the camshaft timing gear set bolt with the number three camshaft lifted up. Remove the number three camshaft and camshaft timing gear with the number two chain.
  44.  
  45. Tie the number one chain to the side. Be careful not to drop anything inside the timing chain cover.
  46.  

To install:


NOTE
Keep the camshaft level while it is being installed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust.

  1. Align the yellow mark link with the timing mark (2 dot mark) of the camshaft timing gear. Apply new engine oil to the thrust portion and journal of the camshafts.

    Click image to see an enlarged view

    Fig. Bank 2 camshaft number three alignment marks-4.0L engine

  2.  
  3. Temporarily install the number one chain onto the number two chain of the camshaft timing gear.
  4.  
  5. Align the knock pin hole of the camshaft timing gear with the knock pin of the number three camshaft. Insert the number three camshaft into the camshaft timing gear.
  6.  
  7. Temporarily install the camshaft timing gear set bolt. Install the number three camshaft onto the left cylinder head with the cam lobes of the number two cylinder facing downward, as indicated in the illustration.

    Click image to see an enlarged view

    Fig. Bank 2 camshaft number three lobe installation positioning-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 camshaft number three bearing cap bolt installation sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 camshaft number three bearing cap bolt torque sequence-4.0L engine

  8.  
  9. Install the four bearing caps, in the proper location. Apply a light coat of engine oil to the threads and under the heads of the cap bolts.
  10.  
  11. Using several steps, uniformly install and tighten the bearing cap bolts in the proper sequence to 80 inch lbs. for the 10mm bolts and 18 ft. lbs. for the 12mm bolts.
  12.  
  13. Rotate the number one camshaft clockwise, using a wrench so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap.
  14.  
  15. Align the paint mark of the number one chain with the timing mark of the camshaft timing gear.
  16.  
  17. Hold the hexagonal portion of the number three camshaft with a wrench, and tighten the camshaft timing gear set bolt to 74 ft. lbs.
  18.  
  19. While pushing in on the number three chain tensioner, insert a 0.039 inch pin into the hole to hold it.
  20.  
  21. Temporarily install the camshaft timing gear and chain tensioner number three and align the yellow mark links with the timing marks (1 dot mark and 2 dot marks) on the camshaft timing gears. Tighten the bolt to 14 ft. lbs.
    NOTE
    Keep the camshaft level while it is being installed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust.

  22.  
  23. Align the knock pin hole in the camshaft timing gear with the knock pin of the number four camshaft, and insert the number four camshaft into the camshaft timing gear.
  24.  
  25. Temporarily install the camshaft timing gear set bolt.
  26.  
  27. Install the four bearing caps in the proper location. Apply a light coat of clean engine oil to the threads and under the heads of the bolts.
  28.  
  29. Using several steps, uniformly install and tighten the eight bearing cap bolts in sequence to 80 inch lbs, for the 10mm head bolts and 18 ft. lbs. for the 12mm head bolts.

    Click image to see an enlarged view

    Fig. Bank 2 camshaft number four bearing cap bolt installation sequence-4.0L engine



    Click image to see an enlarged view

    Fig. Bank 2 camshaft number four bearing cap bolt torque sequence-4.0L engine

  30.  
  31. Hold the hexagonal portion of the number four camshaft, with a wrench, and install the camshaft timing gear set bolt and tighten it to 74 ft. lbs.
  32.  
  33. Remove the pin from the number three chain tensioner.
  34.  
  35. Release the chain tension between the camshaft timing gear (RH bank) and the crankshaft timing gear by turning the crankshaft pulley clockwise slightly.
  36.  
  37. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner. While turning the stopper plate of the tensioner counterclockwise, insert a 0.138 inch bar into the holes in the stopper plate and tensioner to hold the stopper plate. Install the two chain tensioner bolts and tighten to 7.4 ft. lbs. Remove the bar from the chain tensioner.
  38.  
  39. Position the number one cylinder at TDC of the compression stroke. Inspect the valve clearance, adjust as required.
  40.  
  41. Apply a continuous bead (0.08-0.12 inch) of seal packing, part number 08826-00080 or equivalent, to the cylinder head as indicated in the illustration. Install the seal washers onto the bolts. Install the cylinder head cover bolts and nuts. Tighten bolts -A- to 7.4 ft. lbs. Tighten bolts -B- to 80 inch lbs. Tighten nuts to 80 inch lbs.
    NOTE
    Be sure to remove any oil from the contact surfaces of the cylinder head cover and the cylinder head. Install the cover within three minutes after applying the seal packing. Tighten the bolts to specification within fifteen minutes after installing the cover. Do not add engine oil for at least two hours after installing the cover.



    Click image to see an enlarged view

    Fig. Bank 2 cylinder head cover bolt sealant application and bolt identification-4.0L engine

  42.  
  43. Continue the installation in the reverse order of the removal procedure.
  44.  
  45. Be sure to fill the engine with the proper grade and type engine coolant.
  46.  
  47. Be sure to fill the engine with the proper grade and type engine oil.
  48.  
  49. Start the engine and check for leaks. Correct as required.
  50.  

3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Engine undercover
     

  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Air cleaner cap
     
    Mass Air Flow (MAF) meter and the resonator
     
    Actuator cable with the bracket, if equipped with cruise control
     
    Accelerator cable
     
    Throttle cable, if equipped with an automatic transmission
     
    Heater hose
     
    Upper radiator hose from the engine
     

  8.  
  9. Remove the power steering drive belt, as follows:
    1. Stretch the belt and loosen the fan pulley mounting nuts.
    2.  
    3. Loosen the lockbolt, pivot bolt and adjusting bolt and remove the drive belt from the engine.
    4.  

  10.  
  11. Remove or disconnect the following:

    Air conditioning drive belt, by loosening the idle pulley nut and adjusting bolt
     
    Loosen the alternator lockbolt, pivot bolt and adjusting bolt
     
    Alternator drive belt
     
    No. 2 fan shroud, by removing the 2 clips
     
    Fan with the fluid coupling and fan pulleys
     
    Power steering pump and move it aside without disconnecting the lines
     
    Compressor and move it aside without disconnecting the lines, if equipped with air conditioning
     
    Air conditioning bracket, if equipped with air conditioning
     
    Spark plug wires with the ignition coils
     
    Spark plugs
     
    Camshaft Position (CMP) sensor connector, from the No. 2 timing belt cover
     
    3 spark plug wire clamps from the No. 2 timing belt cover
     
    6 bolts and the timing belt cover
     
    Power steering adjusting strut by removing the nut
     
    Fan bracket by removing the bolt and nut
     

  12.  
  13. Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke, as follows:
    1. Turn the crankshaft pulley and align its groove with the timing mark0
    2.  
    3. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees).
    4.  

  14.  
  15. Remove or disconnect the following:

    Timing belt tensioner, by alternately loosening the 2 bolts
     
    Pulley bolt, the timing pulley and the knock pin, using Variable Pin Wrench Set 09960-10010
     
    Both timing pulleys with the timing belt
     
    No. 2 idler pulley
     
    Alternator
     
    Positive Crankcase Ventilation PCV hoses
     
    Water bypass hoses
     
    Air assist hose from the intake air connector
     
    2 vacuum sensing hoses from the Vacuum Switching Valve (VSV)
     
    Evaporative Emissions (EVAP) hose
     
    Air hose from the power steering
     
    Air hose from the air conditioning idle up valve, if equipped with air conditioning
     
    4 bolts, 2 nuts and the air intake chamber assembly
     
    Intake air connector
     
    Camshaft Position (CMP) sensor
     
    No. 3 (rear) timing belt cover by removing the 6 bolts
     
    8 bolts, seal washers, both cylinder head cover and gaskets
     
    Semi-circular plugs
     

  16.  
  17. Remove the right exhaust camshafts, as follows:
    1. Bring the service bolt hole of the driven sub-gear upward by turning the hexagon head portion of the exhaust camshaft with a wrench.
    2.  
    3. Align the timing mark (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
    4.  
    5. Secure the exhaust camshaft sub-gear to the driven gear with a service bolt (6mm diameter, 16-20mm bolt length and 1.0mm in thread pitch).
    6.  

  18.  


NOTE
When removing the camshaft, be sure the torsional spring force of the sub-gear has been eliminated by the above operation.

  1. Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown.
  2.  
  3. Remove the bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.
  4.  


NOTE
Do not pry on or attempt to force the camshaft with a tool or other object.

  1. Remove the right-hand intake camshaft, as follows:
    1. Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown.
    2.  
    3. Remove the bearing caps, oil seal and camshaft. Make a note of the bearing cap positions for proper installation.
    4.  

  2.  
  3. Remove the left exhaust camshafts, as follows:
    1. Align the timing mark (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench.
    2.  
    3. Secure the exhaust camshaft sub-gear to the driven gear with a service bolt (6mm diameter, 16-20mm bolt length and 1.0mm in thread pitch).
    4.  

  4.  


NOTE
When removing the camshaft, be sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

  1. Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown.
  2.  
  3. Remove the bearing caps and camshaft. Make a note of the bearing cap positions for proper installation.
  4.  

  1. Remove the left-hand intake camshaft, as follows:
    1. Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown.
    2.  
    3. Remove the bearing caps, oil seal and camshaft. Make a note of the bearing cap positions for proper installation.
    4.  

  2.  
  3. Remove the valve lifters and shims from the cylinder head. Arrange the valve lifters and shims in correct order.
  4.  

To install:

  1. Clean all surfaces.
  2.  
  3. Install the valve lifters and shims. Check that the valve lifter rotates smoothly by hand.
  4.  
  5. Install the right intake camshaft, as follows:
    1. Apply engine oil to the thrust portion of the intake camshaft.
    2.  
    3. Position the intake camshaft at 90 degrees angle of the timing mark (2 dot marks) on the cylinder head.
    4.  
    5. Install the bearing caps in their proper locations. Apply a light coat of engine oil to the threads and install the cap bolts.
    6.  
    7. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
    8.  
    9. Uniformly tighten the cap bolts in the sequence shown to 12 ft. lbs. (16 Nm).
    10.  

  6.  
  7. Install the right exhaust camshaft, as follows:
    1. Apply engine oil to the thrust portion of the intake camshaft.
    2.  
    3. Align the timing marks (2 dot marks) of the camshaft drive and driven gears.
    4.  
    5. Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other. Install the bearing caps in their proper locations.
    6.  
    7. Apply a light coat of engine oil to the threads and install the cap bolts.
    8.  
    9. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
    10.  
    11. Uniformly tighten the cap bolts in the sequence shown to 12 ft. lbs. (16 Nm).
    12.  
    13. Remove the service bolt from the driven sub-gear. Check that the intake and exhaust camshafts turns smoothly.
    14.  
    15. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
    16.  

  8.  
  9. Install the left intake camshaft, as follows:
    1. Apply engine oil to the thrust portion of the intake camshaft.
    2.  
    3. Position the intake camshaft at 90 degrees angle of the timing mark (1 dot mark) on the cylinder head.
    4.  
    5. Install the bearing caps in their proper locations. Apply a light coat of engine oil to the threads and install the cap bolts.
    6.  
    7. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
    8.  
    9. Uniformly tighten the cap bolts in the sequence shown to 12 ft. lbs. (16 Nm).
    10.  

  10.  
  11. Install the left exhaust camshaft, as follows:
    1. Apply engine oil to the thrust portion of the intake camshaft.
    2.  
    3. Align the timing marks (1 dot mark) of the camshaft drive and driven gears.
    4.  
    5. Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other. Install the bearing caps in their proper locations.
    6.  
    7. Apply a light coat of engine oil to the threads and install the cap bolts.
    8.  
    9. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
    10.  
    11. Uniformly tighten the cap bolts in the sequence shown to 12 ft. lbs. (16 Nm).
    12.  
    13. Remove the service bolt.
    14.  

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

    Semi-circular plugs
     
    Cylinder head covers. Tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
     
    Alternator bracket. Tighten the bolts to 14 ft. lbs. (18 Nm).
     
    No. 3 timing belt cover. Tighten the 6 bolts to 80 inch lbs. (9 Nm).
     
    CMP sensor. Tighten it to 71 inch lbs. (8 Nm).
     
    Intake air connector
     
    Hoses
     
    Alternator but do not tighten the bolts and nuts at this time
     
    No. 2 timing belt idler. Tighten the bolt to 30 ft. lbs. (40 Nm).
     

  16.  


NOTE
Check that the pulley bracket moves smoothly.

 
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