Tracker 2000-2004

Camshaft, Bearings & Lifters

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Inspection



1.6L Engine
  1. Inspect the camshaft journals and the lobes for wear or for scoring.
  2.  
  3. Using outside micrometer J-26900-2, measure the height of the intake lobes and of the exhaust lobes.

    Click image to see an enlarged view

    Fig. Using outside micrometer to measure height of intake and exhaust lobes

  4.  
  5. Standard camshaft intake lobe height is 36.171-36.331mm (1.4241-1.4303 in) and minimum camshaft intake lobe height is 36.071mm (1.4202 in). If any of the camshaft lobes do not meet the specifications, replace the camshaft.
  6.  
  7. Standard camshaft exhaust lobe height is 36.356-36.516mm (1.4314-1.4376 in) and minimum camshaft exhaust lobe height 36.256mm (1.4275 in). If any of the camshaft lobes do not meet the specifications, replace the camshaft.
  8.  
  9. Place the camshaft in two V-Blocks, and use dial indicator J-7872 in order to measure the runout of the camshaft. Camshaft runout maximum is 0.10mm (0.0039 in).

    Click image to see an enlarged view

    Fig. Place the camshaft in two V-Blocks in order to measure the runout of the camshaft

  10.  
  11. Inspect the cylinder head for scoring in the camshaft journals.
  12.  
  13. Inspect the camshaft journal caps for scoring.
  14.  
  15. Clean the cylinder head.
  16.  
  17. Wash the cylinder head in solvent.
  18.  
  19. Inspect the cylinder head for cracks or for other signs of damage.
  20.  

2.0L Engine
  1. Inspect the camshaft journals and the lobes for wear or for scoring.
  2.  
  3. Using outside micrometer J-26900-2, measure the height of the intake lobes and of the exhaust lobes.

    Click image to see an enlarged view

    Fig. Using outside micrometer to measure height of intake and exhaust lobes

  4.  
  5. Standard camshaft intake lobe height is 40.402-40.562mm (1.5906-1.5969 in) and minimum camshaft intake lobe height is 40.202mm (1.5827 in). If any of the camshaft lobes do not meet the specifications, replace the camshaft.
  6.  
  7. Standard camshaft exhaust lobe height is 39.921-40.081mm (1.5717-1.5780 in) and minimum camshaft exhaust lobe height 39.721mm (1.5638 in). If any of the camshaft lobes do not meet the specifications, replace the camshaft.
  8.  
  9. Place the camshaft in two V-Blocks, and use dial indicator J-7872 in order to measure the runout of the camshaft. Camshaft runout maximum is 0.10mm (0.0039 in).

    Click image to see an enlarged view

    Fig. Place the camshaft in two V-Blocks in order to measure the runout of the camshaft

  10.  
  11. Inspect the cylinder head for scoring in the camshaft journals.
  12.  
  13. Inspect the camshaft journal caps for scoring.
  14.  
  15. Clean the cylinder head.
  16.  
  17. Wash the cylinder head in solvent.
  18.  
  19. Inspect the cylinder head for cracks or for other signs of damage.
  20.  

2.5L Engine
  1. Inspect the camshaft journals and the lobes for wear or for scoring.
  2.  
  3. Using outside micrometer J-26900-2, measure the height of the intake lobes and of the exhaust lobes.

    Click image to see an enlarged view

    Fig. Using outside micrometer to measure height of intake and exhaust lobes

  4.  
  5. Standard camshaft intake lobe height is 39.445-39.605mm (1.5530-1.5593 in) and minimum camshaft intake lobe height is 39.400mm (1.5512 in). If any of the camshaft lobes do not meet the specifications, replace the camshaft.
  6.  
  7. Standard camshaft exhaust lobe height is 39.428-39.588mm (1.5523-1.5586 in) and minimum camshaft exhaust lobe height 39.400mm (1.5512 in). If any of the camshaft lobes do not meet the specifications, replace the camshaft.
  8.  
  9. Place the camshaft in two V-Blocks, and use dial indicator J-7872 in order to measure the runout of the camshaft. Camshaft runout maximum is 0.10mm (0.0039 in).

    Click image to see an enlarged view

    Fig. Place the camshaft in two V-Blocks in order to measure the runout of the camshaft

  10.  
  11. Inspect the cylinder head for scoring in the camshaft journals.
  12.  
  13. Inspect the camshaft journal caps for scoring.
  14.  
  15. Clean the cylinder head.
  16.  
  17. Wash the cylinder head in solvent.
  18.  
  19. Inspect the cylinder head for cracks or for other signs of damage.
  20.  

Removal & Installation



1.6L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Radiator
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Camshaft sprocket
     
    Valve cover
     
    Distributor and case, if equipped
     
    Camshaft Position (CMP) sensor and case, if equipped
     

  6.  
  7. Loosen the rocker arm locknuts and back the valve adjusters off until all rocker arms move freely with no tension.
  8.  
  9. Remove or disconnect the following:

    Camshaft bearing caps. Loosen the bolts in reverse of the tightening sequence.
     
    Camshaft

    Click image to see an enlarged view

    Fig. Camshaft housing torque sequence-1.6L engine



    Click image to see an enlarged view

    Fig. Exploded view of the valve train components-1.6L engine

     

  10.  

To install:

  1. Install or connect the following:

    Camshaft
     
    Camshaft bearing caps. Tighten the bolts in sequence to 96 inch lbs. (11 Nm).
     
    CMP sensor and case, if equipped
     
    Distributor and case, if equipped
     
    Camshaft sprocket. Tighten the bolt to 44 ft. lbs. (60 Nm).
     
    Timing belt and adjust the valve clearance
     
    Valve cover
     
    Front cover
     
    Crankshaft pulley. Tighten the bolts to 12 ft. lbs. (16 Nm).
     
    Accessory drive belts
     
    Radiator
     
    Negative battery cable
     

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

2.0L SOHC Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for installation.



    Negative battery cable
     
    Oil pan
     
    Valve cover
     
    Accessory drive belts
     
    Crankshaft pulley
     
    Front cover
     
    Secondary timing chain
     
    Camshaft Position (CMP) sensor
     



    Camshaft bearing caps. Loosen the bolts in several steps in reverse of the tightening sequence.
     
    Camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Camshaft housing torque sequence-2.0L engines

     

  8.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters in their original positions
     
    Camshafts
     
    Camshaft bearing caps in their original positions. Tighten the bolts in several steps in sequence to 96 inch lbs. (11 Nm).
     
    CMP sensor
     
    Secondary timing chain
     
    Front cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Accessory drive belts
     
    Valve cover
     
    Oil pan
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.

  8.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Oil pan
     
    Accessory drive belts
     
    Water pump pulley
     
    Crankshaft pulley
     
    Timing chain cover
     

  8.  
  9. Align the timing marks as shown.
    WARNING
    Do not allow the crankshaft or camshafts to rotate once the timing chains have been removed. Valve or piston damage could result.



    Click image to see an enlarged view

    Fig. Timing mark alignment-2.5L engine

  10.  
  11. Remove or disconnect the following:
    NOTE
    Keep all valvetrain components in order for assembly.



    Left bank secondary timing chain
     
    Primary timing chain
     
    Valve covers
     



    Right bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Camshaft Position (CMP) sensor
     
    Left bank camshaft bearing caps. Loosen the bolts in several steps and in the sequence shown.
     
    Left bank camshafts
     
    Hydraulic lash adjusters

    Click image to see an enlarged view

    Fig. Left bank camshaft housing loosening sequence-2.5L engine



    Click image to see an enlarged view

    Fig. Right bank camshaft housing loosening sequence-2.5L engine

     

  12.  

To install:

  1. Install or connect the following:
    WARNING
    Wait 1 / 2 hour after installing the lash adjusters and camshafts before cranking or starting the engine to allow the lash adjusters to bleed down. Operating the engine before this time period may result in interference between the valves and pistons.



    Hydraulic lash adjusters in their original positions
     
    Left bank camshafts
     
    Left bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     
    CMP sensor
     
    Right bank secondary timing chain, exhaust and intake camshafts as an assembly
     
    Right bank camshaft bearing caps. Tighten the bolts in several steps and in reverse of the loosening sequence to 102 inch lbs. (12 Nm).
     



    Valve covers. Tighten the bolts to 90 inch lbs. (10.5 Nm).
     
    Primary timing chain
     
    Left bank secondary timing chain
     
    Timing chain cover
     
    Crankshaft pulley. Tighten the bolt to 109 ft. lbs. (148 Nm).
     
    Water pump pulley
     
    Accessory drive belts
     
    Oil pan
     
    Intake manifold
     
    Negative battery cable
     

  2.  
  3. Fill the crankcase to the correct level.
  4.  
  5. Fill the cooling system.
  6.  
  7. Start the engine and check for leaks.
  8.  

 
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