Camshaft

Removal

1. Remove or reposition radiator, A/C condenser and grille components as necessary to provide clearance to remove camshaft. Remove the cylinder front cover and the timing chain.

2. Remove the intake manifold and related parts.

3. Remove the valve rocker arm covers. Loosen the valve rocker arm fulcrum bolts and rotate the rocker arms to the side.

4. Remove the valve push rods and tappets as outlined.

    CAUTION: Use caution to avoid damaging the camshaft bearings.

5. Remove the camshaft thrust plate. Carefully remove the camshaft by pulling toward the front of the engine.

Installation

1. Oil the camshaft journals with Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent and apply Multi-Purpose Grease D0AZ-19584-AA (ESR-M1C159-A and ESB-M1C93-A) or equivalent to the lobes. Carefully slide the camshaft through the bearings. Install the camshaft thrust plate with groove toward the cylinder block. Check camshaft end play. Refer to Section 03-00. If not within specification, replace camshaft thrust plate.

2. Install the tappets and push rods as outlined.

3. Apply Multi-Purpose Grease D0AZ-19584-AA (ESR-M1C159-A and ESB-M1C93-A) or equivalent to the valve stem tips. Lubricate the rocker arms and fulcrum seats with Engine Assembly Lubricant D9AZ-19579-D (ESR-M99C80-A) or equivalent. Position the rocker arms over the push rods.

4. Install the upper and lower intake manifolds and related parts. Tighten intake manifold bolts in sequence to 31-34 Nm (23-25 lb-ft) for the lower manifold and 16-24 Nm (12-18 lb-ft) for the upper manifold.

5. Connect wiring to sensors.

6. Connect the accelerator linkage. Connect speed control cable, if so equipped.

7. Connect the heater hoses at the intake manifold. Position and connect the fuel lines.

8. Replace the crankshaft front oil seal. Install the timing chain, cylinder front cover and related parts.

9. On vehicles equipped with air conditioning, install the air conditioning condenser.

10. Position the fan shroud over the fan. Install the radiator and connect the upper and lower radiator hoses.

11. Connect the transmission oil cooler lines (AOD transmission).

12. Install the fan shroud and air cleaner tube attaching screws.

13. With No. 1 piston on TDC at the end of the compression stroke, position the distributor in the block with the rotor at the No. 1 firing position.
    
    
    
    

14. If any valve train components have been replaced, perform Valve Clearance Adjustment as outlined.

15. Clean the valve rocker arm covers and the cylinder head gasket surface. Position the valve rocker cover gaskets.

16. Position the covers on the cylinder heads. Install the bolts. Tighten the bolts to 16-20 Nm (12-15 lb-ft).

17. Install the distributor cap and adapter. Position the spark plug wires in the harness brackets on the rocker arm cover attaching stud and connect the wires to the plugs. Refer to Section 03-07B for special installation instructions. Connect the high tension lead at the distributor.

18. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of engine oil. Connect vacuum lines as required.

19. Install the intake duct assembly.

20. Start engine and operate at fast idle and check all hose connections and gaskets for leaks.
    
    
    
    
    

    Item	Part Number	Description
    1	6256	Camshaft Sprocket
    2	6268	Timing Chain
    3	—	Bearings
    4	6266	Camshaft Rear Bearing Bore Plug
    5	6250	Camshaft
    6	391269	Dowel Pin
    7	6269	Thrust Plate
    8	390392	Thrust Plate Bolt (2 Req'd)
    9	43002	Bolt
    10	6278	Flat Washer