240 L6-2383cc 2.4L DSL SOHC D24 FI (1982)
Camshaft: Service and Repair
Fig. 1 Engine at TDC and injection
1.
Remove valve cover, then the front and rear timing belt covers.
2.
Set engine to TDC and injection position (compression stroke) for No. 1 cylinder. Both No. 1 cylinder camshaft lobes should point up at equal
angles and flywheel timing mark should be at zero (0), Fig. 1.
3.
Loosen water pump retaining bolts to relieve timing belt tension. Tighten two lower bolts to avoid coolant loss and remove timing belt.
4.
Using wrench 5199 or equivalent to hold sprocket, remove camshaft center bolt. Camshaft must not be allowed to rotate. Tap sprocket to loosen it
from tapered end.
5.
Remove two upper belt shield retaining bolts, then push shield away so it clears end of camshaft.
6.
Loosen injection pump bracket bolts to relieve belt tension and remove pump timing belt.
7.
Using wrench 5199 or equivalent to hold camshaft, remove sprocket bolt with wrench 5201 or equivalent. Camshaft must not be allowed to rotate.
8.
Remove vacuum pump and plunger and place pump on wheel house.
9.
Remove camshaft bearing caps 1 and 4.
10.
Loosen cap nuts alternately to avoid unequal stresses on camshaft and remove bearing caps 2 and 3.
11.
Lift out camshaft and remove seals.
12.
Lubricate bearings and contact areas. Place gauge 5190 or equivalent on camshaft rear end and position camshaft on cylinder head. Both No. 1
cylinder cam lobes should point up at equal angles.
13.
Install bearing caps 2 and 3 noting that centers are staggered. Tighten bearing caps alternately to avoid unequal stresses on camshaft.
14.
Place new oil seals on camshaft making sure they are not cocked. Do not bottom seals.
15.
Install camshaft bearing caps 1 and 4 and fit bearing cap 4 against thrust bearing. Torque cap nuts to 15 ft. lbs. (20 Nm).
16.
Press ear seal into position using adapter 5200 or equivalent with bolt for rear camshaft sprocket. Tap front seal into position using adapter 5200
or equivalent.
17.
Attach front timing belt shield, install front camshaft sprocket and timing belt. Install center bolt so sprocket turns freely. Camshaft must not be
allowed to rotate.
Fig. 7 Adjusting timing belt tension
