2. Start the engine and warm it up to normal operating temperature until the electric cooling fan comes on.
3. Run the engine for two minutes to 2500 rpm, check the tappet noise. If the noise remains, continue as follows after stopping the engine.
4. Remove the valve cover, then rotate the crankshaft until the cam lifter being tested points straight up.
5. Using a non-metallic tool, press the plunger down. If the free play is more than 0.1 mm before the valve starts to open, the plunger must be replaced as follows.
6. Remove the air cleaner or fuel injection system components as described in Section 3.
7. Unscrew the nuts, remove the fuel container and the suspension from the valve cover (where it is equipped).
8. Remove the timing belt as described in Chapter 10. Do not remove the tensioner or sprockets from the intermediate shaft and crankshaft.
9. Unscrew the nuts, remove the rear upper cover of the timing belt from the valve cover.
10. Remove the remaining valve cover nuts, noting the location of the wiring harness and ground clamp. Disconnect the crankcase ventilation hose.
11. Remove the reinforcement strips and lift the valve cover.
12. Remove the oil deflector.
13. Remove the gasket from the struts on the cylinder head.
14. Remove the semi-circular gasket from the groove in the front camshaft bearing cover. Also remove the rubber plug on the rear of the cylinder head.
15. Using a screwdriver, remove the front camshaft oil seal.
16. Mark the position and orientation of the camshaft bearing caps, then loosen the nuts evenly and remove the caps.
17. Lift the camshaft from the cylinder head.
18. For folding the pushrods, prepare a box with internal compartments numbered from the front end of the engine.
19. Remove the hydraulic lifters and place them in the box upside down to prevent oil from leaking out.
20. Clean the camshaft (photo), check its condition on the cam lobes and on the bearing journals. Prepare a new seal.
21. Begin assembly by lubricating the hydraulic tappets and installing them in the previously marked positions on the valves.
22. Lubricate the bearing journals on the camshaft, then lower the camshaft into place on the lifters, with the cams for cylinder #1 facing up.
23. Install bearing caps No.2 and 5 (position No.4 is plugged). Install the nuts and tighten them evenly to the torque specified in the Specification. Make sure that the caps are correctly oriented as noted during removal because they are slightly offset.
24. Install bearing caps No.1 and 3, install nuts and tighten evenly to the tightening torque specified in the Specification.
25. Lubricate the lugs and outer rim of the new seal. Position it on the front end of the camshaft and use a socket and mallet to tap it into place until it is level with the cylinder head.
26. Install a new rubber plug and half-round gasket onto the head and front bearing covers, then position the new gasket onto the struts.
27. Install the oil deflector, valve cover and related parts. Tighten the nuts.
28. Install the toothed drive belt as described in Chapter 10.
29. Place the container for the seam and the hanger on the valve cover (if any).
30. Install the air cleaner or fuel injection system components as described in Section 3.
31. If any hydraulic tappet has been replaced, do not start or crank the engine for at least the next thirty minutes. This time is necessary to allow excess oil to flow out of the tappet. If this precaution is not taken, there is a risk of the valve striking the piston.
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