Downloaded from www.Manualslib.com manuals search engine torque. Top edge of tab should be flat against thrust
plate in order to catch oil for chain lubrication.
(5) Place both camshaft sprocket and crankshaft
sprocket on the bench with timing marks on exact
imaginary center line through both camshaft and
crankshaft bores.
(6) Place timing chain around both sprockets.
(7) Turn crankshaft and camshaft to line up with
keyway location in crankshaft sprocket and in cam-
shaft sprocket.
(8) Lift sprockets and chain (keep sprockets tight
against the chain in position as described).
(9) Slide both sprockets evenly over their respec-
tive shafts and use a straightedge to check alignment
of timing marks (Fig. 61).
(10) Install the camshaft bolt/cup washer. Tighten
bolt to 68 N´m (50 ft. lbs.) torque.
(11) Measure camshaft end play. Refer to Specifica-
tions for proper clearance. If not within limits install
a new thrust plate.
(12) Each tappet reused must be installed in the
same position from which it was removed.When
camshaft is replaced, all of the tappets must be
replaced.
(13) Install distributor and distributor drive shaft.
(14) Install push rods and tappets.
(15) Install rocker arms.
(16) Install timing case cover.
(17) Install cylinder head covers.
(18) Install intake manifold.
(19) Install the engine cover.
(20) Install the A/C Condenser (if equipped)
(21) Install the radiator. Refer to Group 7, Cooling
for the correct procedures.
(22) Refill cooling system. Refer to Group 7, Cool-
ing for the correct procedures.
(23) Start engine check for leaks.CAMSHAFT BEARINGS
REMOVAL
NOTE: This procedure requires that the engine is
removed from the vehicle.
(1) With engine completely disassembled, drive out
rear cam bearing core plug.
(2) Install proper size adapters and horseshoe
washers (part of Camshaft Bearing Remover/Installer
Tool C-3132-A) at back of each bearing shell. Drive
out bearing shells (Fig. 62).
INSTALLATION
(1) Install new camshaft bearings with Camshaft
Bearing Remover/Installer Tool C-3132-A by sliding
the new camshaft bearing shell over proper adapter.
(2) Position rear bearing in the tool. Install horse-
shoe lock and by reversing removal procedure, care-
fully drive bearing shell into place.
(3) Install remaining bearings in the same man-
ner. Bearings must be carefully aligned to bring oil
holes into full register with oil passages from the
main bearing. If the camshaft bearing shell oil holes
are not in exact alignment, remove and install them
correctly. Install a new core hole plug at the rear of
camshaft.Be sure this plug does not leak.
DISTRIBUTOR DRIVE SHAFT BUSHING
REMOVAL
(1) Remove distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
(2) Remove the intake manifold. Refer to Intake
Manifold in this section for correct procedure.
(3) Insert Distributor Drive Shaft Bushing Puller
Tool C-3052 into old bushing and thread down until a
tight fit is obtained (Fig. 63).
Fig. 61 Alignment of Timing Marks
1 ± TIMING MARKS
Fig. 62 Camshaft Bearings Removal/Installation with
Tool C-3132-A
1 ± SPECIAL TOOL C-3132±A
2 ± MAIN BEARING OIL HOLE
9 - 172 5.9L ENGINEDN
REMOVAL AND INSTALLATION (Continued)
Downloaded from www.Manualslib.com manuals search engine (4) Hold puller screw and tighten puller nut until
bushing is removed.
INSTALLATION
(1) Slide new bushing over burnishing end of Dis-
tributor Drive Shaft Bushing Driver/Burnisher Tool
C-3053. Insert the tool and bushing into the bore.
(2) Drive bushing and tool into position, using a
hammer (Fig. 64).
(3) As the burnisher is pulled through the bushing,
the bushing is expanded tight in the block and bur-
nished to correct size (Fig. 65).DO NOT ream this
bushing.
CAUTION: This procedure MUST be followed when
installing a new bushing or seizure to shaft may
occur.
(4) Install the intake manifold.
DISTRIBUTOR INSTALLATION
NOTE: Before installing the distributor, the oil
pump drive shaft must be aligned to number one
cylinder.(1) Rotate crankshaft until No.1 cylinder is at top
dead center on the firing stroke.
(2) When in this position, the timing mark of
vibration damper should be under ª0º on the timing
indicator.
(3) Install the shaft so that after the gear spirals
into place, it will index with the oil pump shaft. The
slot on top of oil pump shaft should be aligned
towards the left front intake manifold attaching bolt
hole (Fig. 66).
(4) Install distributor, refer to Group 8D, Ignition
Systems for the proper procedure.
After the distributor has been installed, its rota-
tional position must be set using theSET SYNC
mode of the DRB scan tool. Refer to Checking Dis-
tributor Position following the Distributor Installa-
tion section in Group 8D, Ignition system.
Do not attempt to adjust ignition timing by
rotating the distributor. It has no effect on igni-
tion timing. Adjusting distributor position will
effect fuel synchronization only.
Fig. 63 Distributor Driveshaft Bushing Removal
1 ± SPECIAL TOOL C-3052
2 ± BUSHING
Fig. 64 Distributor Driveshaft Bushing Installation
1 ± SPECIAL TOOL C-3053
2 ± BUSHING
Fig. 65 Burnishing Distributor Driveshaft Bushing
1 ± SPECIAL TOOL C-3053
2 ± BUSHING
Fig. 66 Position of Oil Pump Shaft Slot
1 ± DISTRIBUTOR DRIVE
DN5.9L ENGINE 9 - 173
REMOVAL AND INSTALLATION (Continued)
