Camshaft: Service and Repair

Camshafts

Tools Required:
- Crankshaft Damper Remover T58P-6316-D
- Crankshaft Damper Replacer T74P-6316-B
- Cam Positioning Tool T92P-6256-A
- Valve Spring Compressor T91P-6565-A
- Valve Spring Spacer T91P-6565-AH
- Rotunda Dial Indicator with Bracketry 014-00282


Removal
1. Disconnect negative battery cable.
2. Remove cooling fan and shroud. Radiator Cooling Fan

3. Relieve fuel system pressure and disconnect fuel lines. Fuel Pressure Release

4. Remove air inlet tube.
5. Remove wiper module. Service and Repair

6. Release belt tensioner and remove accessory drive belt.

CAUTION: Do not pull on ignition wires.

7. Disconnect eight ignition wires from spark plugs.
8. Disconnect ignition wire brackets from camshaft cover studs.
9. Remove two bolts retaining ignition wire tray to coil brackets.
10. Remove bolt retaining air conditioner high pressure line to RH coil bracket.
11. Disconnect both ignition coils and CID sensor.
12. Remove three nuts retaining RH coil bracket to front cover.
13. Remove three nuts retaining LH coil bracket to front cover.
14. Slide ignition coil brackets and ignition wire assembly off mounting studs and remove from vehicle.
15. Remove water pump pulley.
16. Disconnect positive battery cable at power distribution box.






17. Remove retaining bolt from positive battery cable bracket located on the side of RH cylinder head.
18. Disconnect vent hose from canister purge solenoid and position positive battery out of the way.
19. Disconnect canister purge solenoid vent hose from PCV valve and remove PCV valve from camshaft cover.
20. Remove 42-pin engine harness connector from retaining bracket on brake vacuum booster.






21. Disconnect 42-pin connector and transmission harness connector and position out of the way.
22. Disconnect crankshaft position sensor, air conditioning compressor clutch and canister purge solenoid connectors.

23. Raise vehicle on a hoist.

NOTE: The front lower bolt on the power steering pump will not come all the way out.

24. Remove bolts retaining power steering pump to engine block and cylinder front cover.
25. Wire the power steering pump out of the way.
26. Remove four bolts retaining oil pan to front cover.
27. Remove crankshaft damper retaining bolt and washer from crankshaft.






28. Install Crankshaft Damper Remover T58P-6316-D on damper and pull damper from crankshaft.
29. Position drain pan under oil filter and remove oil filter.
30. Disconnect EVO sensor and oil sending unit.
31. Remove oil filter and position EVO sensor and oil pressure sending unit harness out of the way.
32. Lower vehicle.
33. Remove nine bolts and two stud bolts retaining RH camshaft cover to cylinder head and remove camshaft cover.






34. Remove eight bolts and three stud bolts retaining LH camshaft cover to cylinder head and remove camshaft cover.






35. Remove seven stud bolts and four bolts retaining front cover to engine. Remove front cover.
36. Remove timing chains as outlined.






37. Rotate crankshaft counterclockwise 45 degrees from toe.

CAUTION: Crankshaft must be in this position prior to rotating camshafts or damage to pistons and/or valve train will result.

NOTE: This ensures that all pistons are below the top of the engine block deck face.






38. Install Valve Spring Compressor T91P-6565-A, under camshaft and on top of valve spring retainer.

NOTE: A Valve Spring Spacer T91P-6565-AH must be installed between spring coils and camshaft must be at base circle before compressing valve spring. Rotate camshaft as required until all roller followers are removed.

39. Compress valve spring far enough to remove roller follower.
40. Repeat Steps 38 and 39 until all roller followers are removed.






41. Remove 14 bolts retaining camshaft cap cluster assemblies to cylinder head.
42. Tap upward on camshaft cap at position shown and gradually lift camshaft cap cluster from cylinder head.






43. Remove camshaft straight upward to avoid bearing damage.

NOTE: Steps 38 through 43 will remove only one camshaft. If both camshafts are being serviced, repeat Steps 38 through 43 to remove the other camshaft.

Installation
1. Clean and inspect camshaft cover, front cover and cylinder head sealing surfaces.
2. Position camshaft on cylinder head. Apply oil to journals and lobes of camshaft.
3. Install and seat camshaft cap cluster assemblies. Hand-start 14 bolts.

NOTE: Each camshaft cap cluster assembly is tightened individually.






4. Tighten camshaft cap cluster retaining bolts in sequence to 8-12 N-m (6.0-8.8 lb-ft).
5. Loosen 14 camshaft cap cluster retaining bolts approximately two turns or until head of bolt is free.

NOTE: Camshaft should turn freely with a slight drag.

6. Retighten all bolts in sequence to 8-12 N-m (6.0-8.8 lb-ft).
7. Check camshaft end play using Rotunda Dial Indicator with Bracketry 014-00282 or equivalent.
8. If necessary, install Cam Positioning Tool T92P-6256-A on flats of camshaft and install spacer and camshaft gear. Install bolt and washer and tighten to 110-130 N-m (81-95 lb-ft).

NOTE: Valve Spring Spacer T91P-6565-AH must be installed between spring coils and the camshaft must be at base circle prior to compressing valve spring. Rotate camshaft as necessary until all roller followers are installed.

9. Install Valve Spring Compressor T91P-6565-A, under camshaft and on top of valve spring retainer. Install lash adjusters.
10. Compress valve spring far enough to install roller follower.
11. Repeat Steps 8 and 9 until all roller followers are installed. Remove Valve Spring Spacer from coil springs.

NOTE: Steps 2 through 11 will install only one camshaft. If both camshafts are being serviced, repeat Steps 2 through 11 to install the other camshaft.

CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as TDC.






12. Rotate crankshaft clockwise 45 degrees.

NOTE: This will position crankshaft at TDC.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and/or pistons will result.

13. Install timing chains as outlined.
14. Inspect and replace front cover seal and gasket.






15. Apply Silicone Gasket and Sealant F1AZ-19562-A (WSE-M4G320-A2) or equivalent in locations shown.
16. Install front cover on engine.
17. Install front cover studs bolts and eight bolts retaining front cover to engine. Tighten to 20-30 N-m (15-22 lb-ft).
18. Apply Silicone Gasket and Sealant F1AZ-19562-A (WSE-M4G320-A2) or equivalent both places front cover meets cylinder head.
19. Position and using a suitable sealer, glue gaskets into camshaft covers and install camshaft covers onto cylinder heads.
20. Install bolts and stud bolts into RH camshaft cover. Tighten all bolts to 8-12 N-m (6.0-8.8 lb-ft).






21. Install bolts and stud bolts into LH camshaft cover. Tighten all bolts to 8-12 N-m (6.0-8.8 lb-ft).
22. Raise vehicle.
23. Connect EVO sensor and oil sending unit.






24. Apply Silicone Gasket and Sealant F1AZ-19562-A (WSE-M4G320-A2) or equivalent in keyway of damper as shown.
25. Position damper on crankshaft. Ensure crankshaft key and keyway are aligned.






26. Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft damper.
27. Install damper bolt and washer. Tighten to 155-165 N-m (114-121 lb-ft).
28. Install four bolts retaining oil pan to front cover. Tighten to 20-30 N-m (15-22 lb-ft).
29. Position power steering pump on engine and install four retaining bolts. Tighten to 20-30 N-m (15-22 lb-ft).
30. Lower vehicle.
31. Connect air conditioning compressor, HDR sensor and canister purge solenoid.
32. Connect 42-pin engine harness connector and transmission harness connector.






33. Install 42-pin connector on retaining bracket on vacuum brake booster.
34. Install PCV valve in RH camshaft cover and connect canister purge solenoid vent hose.
35. Position positive battery cable harness on RH cylinder head.
36. Install bolt retaining cable bracket to cylinder head.
37. Connect vent hose to canister purge solenoid.
38. Connect positive battery cable at power distribution box and battery.
39. Install water pump pulley and tighten bolts to 20-30 N-m (15-22 lb-ft).
40. Position ignition coil brackets and ignition wire assembly onto mounting studs.
41. Install seven nuts retaining coil brackets to front cover. Tighten to 20-30 N-m (15-22 lb-ft).
42. Connect both ignition coils and CID sensor.
43. Position air conditioner high pressure line on RH coil bracket and install bolt.
44. Connect ignition wires to spark plugs and install bracket onto camshaft cover studs.
45. Install accessory drive belt.
46. Install wiper module. Service and Repair

47. Connect fuel lines. Service and Repair

48. Install cooling fan and shroud. Fill cooling system.
49. Install air inlet tube.
50. Connect negative battery cable.
51. Start engine and check for leaks.
52. Check and add oil as needed.