Camshaft and Valve Lifters

REMOVAL & INSTALLATION

2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Drain and recycle the engine coolant.
3. Drain and recycle the engine crankcase.
4. Remove or disconnect the following:
   • Negative battery cable

   CAUTION
   Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

5. Positive Crankcase Valve (PCV) hose
6. Valve cover and the upper timing belt cover
7. Rotate the crankshaft clockwise and align the camshaft sprocket timing mark with the timing mark on the cylinder head.
8. Remove or disconnect the following:
   • Distributor, matchmark for reassembly
9. Install auto lash adjuster retainer MD998443 to each rocker arm to hold the auto lash adjusters in place
10. Remove or disconnect the following:
    • Rocker arm and shafts

    WARNING
    Do not rotate the crankshaft after the sprocket is removed from the camshaft. Be sure there is no slack in the timing belt. Be sure the timing belt does not disengage from the sprocket. If the crankshaft is rotated or the timing belt position is disturbed, timing belt and sprocket alignment will have to be set.

11. Thrust cage and o-ring
12. Camshaft and the front seal from the engine

    To install:

13. Install or connect the following:
    • Front seal
    • Camshaft, lubricate with engine oil
    • Thrust cage and o-ring. Torque the bolts to 13 ft. lbs. (18 Nm).
    • Rocker arm and shafts. Torque the bolts to 23 ft. lbs. (31 Nm).
14. Remove the auto lash adjuster retainer MD998443 from each rocker arm.
15. Install or connect the following:
    • Valve cover and upper timing belt cover
    • Positive Crankcase Valve (PCV) hose
    • Distributor, aligning the mark made during removal
    • Negative battery cable
16. Start the engine and check for leaks.

3.0L, 3.5L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Drain and recycle the engine coolant.
4. Drain and recycle the engine crankcase.
5. Remove or disconnect the following:
   • Negative battery cable

   CAUTION
   Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative battery cable is disconnected.

6. Intake manifold plenum
7. Valve cover
8. Timing belt
9. Sprocket from the camshaft
10. Install auto lash adjuster retainers SST MD998443 on the rocker arms.
11. Remove or disconnect the following:
    • Distributor and the distributor extension, if equipped
    • Rocker arms, rocker shafts and bearing caps, as an assembly
    • Thrust cage and o-ring
    • Camshaft from the cylinder head
12. Inspect the bearing journals on the camshaft and the cylinder head.

    To install:

13. Lubricate the camshaft journals and camshaft with clean engine oil
14. Install or connect the following:
    • Camshaft in the cylinder head.
    • Thrust cage and o-ring. Torque the bolts to 109 inch lbs. (12 Nm).
    • Rocker arms, rocker arm shaft and the rocker shaft spring.
15. Temporarily tighten the rocker shaft with the bolts positioned so that the intake valve rocker arms do not push the valves.
16. Install or connect the following:
    • Rocker shaft spring from above and mount it at right angles to the plug guide.
17. Before installing the exhaust rocker arms and the rocker arm shaft, mount the rocker shaft spring.
18. Remove the SST used to hold the lash adjuster in position.
19. Check to ensure that the flat side of the rocker shaft is perpendicular to the cylinder head, and facing the valves.
20. Gradually tighten the bearing caps in 2 or 3 steps. In the final step tighten to 23 ft. lbs. (31 Nm).
21. Install or connect the following:
    • Distributor, if removed
    • Sprockets. Torque the bolts to 65 ft. lbs. (88 Nm).
    • Timing belt and timing belt cover
    • Valve cover. Torque the bolts to 26 inch lbs. (3.4 Nm).
    • Intake manifold plenum
    • Negative battery cable
22. Start the engine and check for leaks and proper operation.
23. Refill the coolant and crankcase.

    Fig. 1: The camshaft bearing caps have identification marks on them — 3.5L engine