Valve Clearance: 2.5L
- Disconnect battery negative cable. Remove canister. Remove canister bracket. Lift and support vehicle. Remove right and left side under covers. Remove right side timing belt cover. Lower vehicle. Remove valve cover. On cylinders No. 1 and No. 3 side, disconnect mass air flow sensor. disconnect blow-by hose from air intake duct. Remove air intake duct and upper cover as a unit. Remove air filter element and filter housing lower case. Disconnect spark plug wires and PCV hose. Remove valve cover.
- On cylinder No. 2 and No. 4 side, disconnect and remove washer tank. Disconnect spark plug wires and PCV hose. Remove the valve cover. Measure and record all valve clearances. Refer to the VALVE CLEARANCE SPECIFICATION table. If not within specifications, remove timing belt, camshaft sprockets, any related parts and camshaft.
- Remove timing belt. Disconnect right and left radiator fan motor connectors. Remove coolant recovery tank from left side of radiator. Remove right and left radiator fan motor and shroud assemblies, being careful not to damage radiator.
- Remove "V" belt cover and "V" belts. Using Crankshaft Pulley Wrench (499977000), secure crankshaft pulley. Using Crankshaft Socket (499987500), remove crankshaft pulley bolt then remove crankshaft pulley. Remove right and left timing belt covers. Remove A/C belt tensioner then remove center timing belt cover. Turn crankshaft and align marks on camshaft and crankshaft sprockets with the notches on right and left timing belt covers and oil pump. See Fig 1.
- If alignment marks and/or arrow mark on timing belt are faded or missing, remark timing belt before removing. As an alternative, timing belt teeth may be counted to establish correct placement of alignment marks. See Fig 2. Loosen 2 tensioner adjuster bolts. Remove idler No. 1. See Fig 1. Remove timing belt.
- Remove Camshaft. Remove ignition coils. Loosen camshaft bearing cap bolts equally in several steps and in sequence. See Fig 4. Remove camshaft bearing caps. Mark bearing caps and arrange in order for installation. Remove camshafts.
- Remove shim from valve lifter. Measure thickness of shim. Using measured valve clearance ("V") and thickness of shim ("T"), determine shim thickness ("S") using the following equations:
- Intake Valve: S = (V + T) - .20 mm
- Exhaust Valve: S = (V + T) - .25 mm
Shims are available in thicknesses from .0917" (2.33 mm) to .1059" (2.69 mm) in .0004" (.02 mm) increments. Install selected shim to valve lifter.
- Install one camshaft at a time. To install camshaft, apply engine oil to lash adjusters and install lash adjusters (if removed). Apply engine oil to camshaft journals. Place camshaft on cylinder head with notch on front end facing appropriate direction. See Fig 5.NOTE: As cap bolts are tightened, clearance between camshaft journal and cylinder head journal should decrease evenly. If clearance does not decrease evenly, loosen bolts and repeat tightening procedure.
- Apply thin coat of sealant to mating surface of front bearing cap. Install camshaft caps, and hand-tighten cap bolts. Tighten cap bolts equally, in sequence. See Fig 6. Tighten each bolt 90-180 degrees in sequence, then repeat until bolts are tightened to specification. See the TORQUE SPECIFICATIONS table in the appropriate ENGINE article in the ENGINES section.
- Apply grease to camshaft oil seal lip, and install oil seal using Camshaft Oil Seal Guide (499597000) and Camshaft Oil Seal Installer (499587100). To install other components, reverse removal procedure.