Camshaft Installation

NOTE: Special Tools Required: 5021, 5025, 5034.

Camshaft & Bearing Shells:

CAMSHAFT INSTALLATION
1. Oil the bearing shells, cam lobes, adjustment washers and tappets (valve depressors).
2. Install tappets (valve depressors).

Camshaft & Tool # 5021:

Applying Sealant To End Caps:

Camshaft Front Seal Installation:

3. Install camshaft and bearing caps:
- Coat sealing surface toward cylinder head of front and rear bearing caps with sealing compound, P/N 1161027-6.
- Position camshaft and rear bearing cap. Guide pin on pulley should point up.
- Use tool 5021 to depress camshaft. Use rear bearing cap to guide.
- Loosely tighten nuts for rear bearing cap.
- Oil and install three caps. Loosely tighten nuts.
- Remove press tool 5021.
- Oil and install center bearing cap.
- Torque bearing cap nuts to 20 Nm (14 ft lbs).
4. Install front oil seal using sleeve 5025. Grease seal and shaft, make sure rubber lip on seal does not become damaged.

Camshaft Pulley Removal:

5. Install camshaft pulley and spacer washer using tool 5034. Torque to 50 Nm (36 ft lbs).

Camshaft & Crankshaft Alignment Marks:

TIMING BELT INSTALLATION

CAUTION: Do not turn crankshaft or camshaft. Pistons may strike valves.

1, Position pulleys according to alignment marks.
- Make sure distributor rotor points toward marking on distributor housing.
2. Position timing belt on crankshaft and intermediate shaft.
3. Stretch timing belt and install it on camshaft and belt tensioner.
- Check that timing belt is correctly positioned and that pulley markings are opposite markings on engine.

Fan Shroud & Pulley:

4. Install belt tensioner nut and washer. Do not tighten nut fully.
5. Pull timing belt to depress tensioner spring and remove locking drill.
- Tensioner spring will tension timing belt.
6. Tighten tensioner nut.
7. Install upper timing belt cover.

FINAL INSTALLATION STEPS/CHECKS/ADJUSTMENTS:
1. Install the following:
- water pump pulley.
- drive belts loosely.
- fan shroud.
- clamp for preheating hose.
- cooling fan.
- engine oil and filter.
2. Tension drive belts:
- With correct tension, drive belts can be depressed 5-10 mm (0.2-0.4 in) with thumb pressure.
3. Adjust valve clearance.
4. Install valve cover and gasket.
5. Run engine warm and check/adjust:
- ignition timing.
- CO.
- idle speed.
- cooling system.
6. Recheck timing belt tension.