Rocker Arm Assembly: Service and Repair

Special Tools:

Removal
1. Remove the battery.
2. Remove the right-hand valve cover.
3. Remove the left-hand valve cover.
4. Remove the crankshaft pulley.





5. Install the crankshaft pulley bolt and washer.

6. CAUTION: Rotate the crankshaft clockwise to position the crankshaft keyway to the 11 o'clock position and the engine to Top Dead Center (TDC) No. 1 cylinder, prior to the removal and installation of the camshafts and the roller followers, or damage to the engine may occur.

CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.





Rotate the crankshaft keyway to position the No. 1 cylinder at Top Dead Center (TDC).
- Rotate the crankshaft keyway clockwise to the 11 o'clock position.

7. NOTE: The right-hand camshafts are in the neutral position.





Rotate the crankshaft clockwise to position the crankshaft keyway in the 3 o'clock position.





8. Rotate the belt tensioner clockwise towards the camshaft drive pulley to relieve the drive belt tension and remove the belt.





9. Remove the water pump drive pulley.
1 Install the special tool.
2 Install the special tool then turn center bolt.
3 Remove the pulley.

10. CAUTION: Protect the camshaft surface when removing the oil seal retainer.





Remove the bolts and the camshaft oil seal retainer.
- Remove and discard the gasket.

11. CAUTION: Cylinder head and camshaft bearing caps are numbered to make sure they are assembled in their original positions. When removed, keep the bearing caps with the cylinder head they were removed from. Do not mix caps.

NOTE: Do not loosen any of the other bolts until the thrust caps are removed.





Remove the right-hand camshaft thrust caps 1R and 5R.
1 Remove the bolts.
2 Remove the camshaft thrust caps.

12. NOTE: Loosen bolts on several passes. Do not remove bolts completely.

NOTE: Camshaft bearing caps are doweled to cylinder head. Use a plastic mallet to loosen caps, if necessary.





Loosen the remaining bolts 7-8 turns in the indicated sequence in several passes to allow the camshafts to be slowly raised.

13. NOTE: If the camshaft followers and lash adjusters are to be reused, mark their positions to make sure they are assembled in the original location.





Remove the twelve right-hand camshaft roller finger followers.

14. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.





Rotate the crankshaft clockwise two revolutions and position the crankshaft keyway in the 1l o'clock position.
- The left-hand camshafts will be in the neutral position.

15. CAUTION: Cylinder head and camshaft bearing caps are numbered to make sure they are assembled in their original position. When removed, keep the bearing caps with the cylinder head they were removed from. Do not mix caps.

NOTE: Do not loosen any of the other bolts until the thrust caps are removed.





Remove the left-hand camshaft thrust caps 1L and 5L.
1 Remove the bolts.
2 Remove the camshaft thrust caps.

16. NOTE: Loosen bolts on several passes. Do not remove bolts completely.





Loosen the remaining bolts 7 turns in the indicated sequence to allow the camshafts to be raised.

17. NOTE: If the camshaft followers and lash adjusters are to be reused, mark; their positions to make sure they are assembled in the original location.





Remove the twelve left-hand camshaft roller finger followers.

Installation

1. CAUTION: The crankshaft keyway must be in the 11 o'clock position prior to installation of the roller finger followers. Failure to do so may lead to engine damage.

NOTE: Make sure the roller finger followers are installed in their original locations





Install the twelve left-hand camshaft roller finger followers.
- Apply Engine assembly lubricant and lubricate the roller finger followers before installation

2. CAUTION: Install the camshaft journal thrust caps last or damage to the thrust caps may occur.

CAUTION: Use thrust caps 1L and 5L to align camshaft end play prior to tightening the other bearing caps.





Install and tighten the left-hand cylinder head bearing caps in the indicated sequence in several passes.

3. CAUTION: Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.

NOTE: The right-hand camshafts are in the neutral position.





Rotate the crankshaft clockwise to position the crankshaft keyway in the 3 o'clock position.

4. CAUTION: The crankshaft keyway must be in the 3 o'clock position prior to installation of the right-hand roller finger followers. Failure to do so may lead to engine damage.

NOTE: Make sure the roller finger followers are installed in their original positions.





Install the twelve right-hand camshaft roller finger followers.
- Apply Engine assembly lubricant and lubricate the roller finger followers before installation.

5. CAUTION: Install the camshaft bearing thrust caps last or damage to the thrust caps may occur.

CAUTION: Use thrust caps 1R and 5R to align camshaft end play prior to tightening the other bearing caps.





Install the camshaft bearing caps (right-hand cylinder head).
- Tighten the bearing caps evenly according to the indicated sequence in several passes.

6. NOTE: Install a new gasket when installing the camshaft oil seal retainer.





Install the camshaft oil seal retainer.
- Make sure that the retainer is correctly located on the dowels.





7. Using the special tool, install the water pump drive pulley.





8. Rotate the belt tensioner towards the camshaft drive pulley.
- Install the drive belt.





9. Remove the crankshaft pulley bolt and washer.
10. Install the right-hand valve cover.
11. Install the left-hand valve cover.
12. Install the crankshaft pulley.
13. Install the battery.