Rocker Arm Assembly: Service and Repair
REMOVAL1. Remove valve covers and gaskets.
2. Remove crankshaft pulley bolt from front of crankshaft, then rotate crankshaft to Top Dead Center (TDC) No. 1 cylinder.
CAUTION: Rotate crankshaft to position crankshaft keyway to the 11 o'clock position and engine to TDC No. 1 cylinder before replacing camshafts and rocker arms, or damage to engine may occur.
3. Verify alignment arrows on camshafts are aligned. If arrows are not aligned, rotate crankshaft one complete revolution.
4. Rotate crankshaft to position crankshaft keyway to three o'clock location. This will position righthand cylinder head camshafts to neutral position (base circle).
Fig. 15 Water pump drive pulley removal:
5. Rotate water pump drive belt tensioner clockwise to release water pump drive belt tension and remove water pump drive belt, then carefully release drive belt tensioner.
6. Remove battery, then, using crankshaft damper remover T58P-6316-D and water pump pulley remover/replacer T94P-6312-AH, or equivalents, with shaft protector and screw, remove water pump drive pulley from lefthand intake camshaft.
Fig. 16 Rear camshaft rear oil seal retainer removal:
7. Remove camshaft rear oil seal bolts, then retainer and gasket from lefthand cylinder head.
8. Remove cylinder head camshaft journal thrust cap bolts and thrust caps from righthand cylinder head, noting following:
a. Remove cylinder head camshaft journal thrust caps first to ensure damage to cylinder head camshaft journal thrust caps does not occur.
b. Cylinder head camshaft journal caps and cylinder heads are numbered to ensure they are assembled in original position. When removed, keep camshaft journal caps from each cylinder head with head they were removed from. Do not mix with camshaft journal caps to ensure damage to cylinder head camshaft journal thrust caps does not occur.
Camshaft journal cap bolt removal sequence:
9. Loosen remaining righthand cylinder head camshaft journal cap bolts seven to eight turns in sequence, in several passes (approximately one to two turns each pass) to allow camshafts to be raised from righthand cylinder head. Do not completely remove bolts.
10. With righthand cylinder head camshaft journal caps and camshafts loose on righthand cylinder head, remove rocker arms. If roller rocker arms are to be reused, mark position or rocker arms to ensure they are assembled in original positions.
11. Rotate crankshaft two revolutions and position crankshaft keyway to 11 o'clock location. This will position lefthand cylinder head camshafts to neutral position (base circle).
12. Verify alignment arrows on camshafts are aligned, then remove cylinder head camshaft journal thrust cap bolts and thrust caps from lefthand cylinder head, noting following:
a. Remove cylinder head camshaft journal thrust caps first to ensure damage to the thrust caps does not occur.
b. Cylinder head camshaft journal caps and cylinder heads are numbered to ensure they are assembled in original position When removed, keep camshaft journal caps from each cylinder head with head they were removed from. Do not mix with camshaft journal caps from another cylinder head.
Camshaft journal cap bolt removal sequence:
13. Loosen remaining lefthand cylinder head camshaft journal cap bolts seven to eight turns in sequence, in several passes (approximately one to two turns each pass) to allow camshafts to be raised from lefthand cylinder head. Do not completely remove bolts.
14. With lefthand cylinder head camshaft journal caps and camshafts loose on lefthand cylinder head, remove rocker arms.
NOTE: If roller rocker arms are to be reused, mark positions of rocker arms to ensure they are assembled in original positions.
INSTALLATION
1. Ensure rocker arms are installed in original locations.
CAUTION: Crankshaft keyway must be at 11 o'clock position before installing rocker arms. Failure to do so may lead to engine damage.
2. Lubricate rocker arms with suitable engine assembly lubricant, then install rocker arms onto lefthand cylinder head under camshafts.
camshaft journal cap bolt tightening sequence.:
3. With lefthand cylinder head rocker arms installed under camshafts, torque lefthand cylinder head camshaft journal cap bolts in sequence, in several passes, to 5.9-8.8 ft lb.
4. Align camshafts in lefthand cylinder head with thrust caps, then install lefthand cylinder head camshaft journal thrust caps. Tighten bolts to 5.9-8.8 ft lb.
5. Rotate crankshaft two revolutions and position crankshaft keyway to three o'clock position. This will position righthand cylinder head camshafts to neutral position (base circle).
6. Ensure rocker arms are installed in original locations. Crankshaft keyway must be at three o'clock position before installing rocker arms. Failure to do so may lead to engine damage.
7. Lubricate rocker arms with suitable engine assembly lubricant, then install rocker arms onto righthand cylinder head under camshafts.
camshaft journal cap bolt tightening sequence.:
8. With righthand cylinder head rocker arms installed under camshafts, torque righthand cylinder head camshaft journal cap bolts in sequence, in several passes, to 5.9-8.8 ft lb. Install cylinder head camshaft journal thrust cap last to ensure damage to No. 1 journal cap does not occur.
9. Align camshafts in righthand cylinder head with thrust caps, then install righthand cylinder head camshaft journal thrust caps.
10. Install camshaft rear oil seal and retainer and gasket onto lefthand cylinder head.
Fig. 19 Water pump drive pulley installation:
11. Using power steering pump pulley replacer tool T91P-3A733-A, screw T94P-6312-AH and replacer cup tool T94P-6312-AH, or equivalents, install water pump drive pulley on lefthand intake camshaft.
12. Rotate water pump drive belt tensioner clockwise and install water pump drive belt, then carefully release drive belt tensioner.
13. Install battery.
14. Install crankshaft pulley bolt, and tighten as follows:
a. Torque crankshaft pulley bolt first to 89 ft lb.
b. Loosen a minimum of one full turn.
c. Torque bolt to 35-39 ft lb.
d. Finally, rotate 85-95°.
e. Install valve covers and valve cover gaskets.