:  Jan 29, 2007


















. Disconnect the battery ground cable.

. Remove the battery tray.

. Raise and support the vehicle.

. Remove the engine front cover.

. Remove the crankshaft position (CKP) sensor.

. Rotate the crankshaft until the flats on the camshafts are parallel with the cylinder head joint faces.

. :
  The engine is now in the SAFE position.

Lock the crankshaft.
  Install the special tool.
  Install the screw.




. Remove the RH variable camshaft timing (VCT) control unit.
  Remove the 3 bolts.
  Remove and discard the O-ring seals.




. Install the special tool to the RH cylinder head.
  Install the 3 bolts.




. Remove the primary timing chain tensioner.
  Remove the 2 bolts.




. Remove the primary timing chain tensioner guide.
  Remove the bolt.




. Remove the primary timing chain.



. Remove the secondary timing chain tensioner and the secondary timing chain.
  Remove the 2 retaining bolts.




.
  : Discard the bolts.

Remove the camshaft sprockets.
  Remove the 2 bolts.




. Remove the special tool from the RH cylinder head.
  Remove the 3 bolts.




.
  : Evenly and progressively, release the camshaft bearing caps.

:
  Remove the camshaft bearing caps. Note: their position, orientation and markings. Each is marked with its position (number) and an orientation (arrow).

Remove the camshaft bearing caps.
  Remove the 20 bolts.




. Remove the camshafts.

. Check and adjust the valve tappet clearances.

. Replace the valve shims, with the smallest shim available.
  Apply a light coat of clean engine oil to the replacement valve shims.

. Install the camshafts.
  Clean the component mating faces.
  Lubricate the journals and camshaft lobes.

. Install the camshaft bearing caps.
  Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).




. Install the sprocket retaining Torx bolts to the camshafts.

.
  : Camshaft lobes must be 180 degrees away from each valve tappet or valve clearance will be incorrect.

Measure and record the tappet clearances.
  Rotate the camshafts using the Torx bolts.




.
  : Evenly and progressively, release the camshaft bearing caps.

:
  Remove the camshaft bearing caps. Note: their position, orientation and markings. Each is marked with its position (number) and an orientation (arrow).

Remove the camshaft bearing caps.
  Remove the 20 bolts.




. Remove the camshafts.

. Remove the valve tappets, replace with selected tappets.

. Install the camshafts.
  Lubricate the journals and camshaft lobes.
  Clean the component mating faces.

. Install the camshaft bearing caps.
  Evenly and progressively tighten the bolts in the sequence shown to 10 Nm (7 lb.ft).

.
  : Camshaft lobes must be 180 degrees away from each valve tappet or valve clearance will be incorrect.

Check valve tappet clearances are correct.
  Rotate the camshafts using the Torx bolts.
  Remove the camshaft Torx bolts after the check is complete.

. Install the special tool to the RH cylinder head.
  Install the 3 bolts.

. Retain the LH secondary timing chain tensioner piston.
  Using 1 mm diameter metal rod, retain the chain tensioner piston.




. Install the secondary timing chain tensioner and chain to the camshaft sprockets.

. :
  Lightly tighten the camshaft sprocket Torx bolts, the sprockets MUST be free to move.

Install the secondary timing chain and sprockets to the camshafts.
  Install the sprocket retaining Torx bolts to the camshafts.

. Install the secondary timing chain tensioner retaining bolts.
  Tighten the bolts to 12 Nm (9 lb.ft).

. Tension the secondary timing chain.
  Remove the retaining rod.

. Install the primary timing chain.
  Make sure the timing chain slack is on the tensioner side of the timing chain.

. Install the primary tensioner guide.
  Tighten the bolts to 12 Nm (9 lb.ft).

.
  : During timing chain tensioner compression, do not release the ratchet stem until the timing chain tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.

Install the primary chain tensioner.
  Using 3 mm diameter metal rod, retain the chain tensioner piston.
  Tighten the bolts to 12 Nm (9 lb.ft).
  Remove the retaining rod.




.
  : The intake camshaft sprocket retaining bolt MUST be tightened before the exhaust camshaft sprocket retaining bolt. Engine damage will occur if this procedure is not followed.

  : Using the special tool, apply force to the tool in a counter-clockwise direction, to tension the primary timing chain on its drive side.

  : Make sure that new bolts are installed.

Install the special tool to the exhaust camshaft sprocket.
  Tighten the intake camshaft sprocket retaining bolt to 120 Nm (88 lb.ft).
  Tighten the exhaust camshaft retaining bolt to 120 Nm (88 lb.ft).




. Remove the special tool from the RH cylinder head.

. Install the RH VCT oil control unit.
  Install the new O-ring seals.
  Tighten the new bolts to 22 Nm (16 lb.ft).

. Remove the crankshaft locking tool.
  Remove the screw.

. Install the CKP sensor.

. :
  Before installing the valve covers, check the valve clearances.

Install the engine front cover.

. Install the battery tray.