Camshaft, Bearings and Lifters

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable. Wait at least 90 seconds before performing any work after the cable has been disconnected on models with an airbag.

   CAUTION
   Some models covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Section 6.

2. Relieve the fuel system pressure.

   CAUTION
   Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

3. Remove the engine wiring from the engine and move it aside.
4. Remove the No. 2 valve cover.
5. Mark the spark plug wires and disconnect. Matchmark the distributor, rotor and cylinder head. Remove the distributor and disconnect the wiring.
6. Remove the PCV hose.
7. Remove the No. 1 valve cover and two half circular plugs.

   Fig. 1: Remove the half circular plugs (half-moons) from the side of the head

8. Remove the chain tensioner and gasket.

   Fig. 2: Remove these bolts to access the tensioner

   Fig. 3: Pull the tensioner out of the engine in the upright position, do not turn it upside down

9. Place matchmarks on the timing sprocket and chain. Hold the intake camshaft with a wrench and remove the sprocket bolt.

   Fig. 4: Place matchmarks on the camshaft timing gear and chain before removal

   Fig. 5: Hold the intake camshaft with a wrench and remove the bolt

   Fig. 6: Be sure to place the wrench on a portion of the camshaft where it will not be damaged

   Fig. 7: The sprocket bolt is a large headed bolt on the front of the cam

   NOTE: It is a good idea to tie the chain and sprocket together with a tie rap.

   Fig. 8: Place a tie rap around the cam sprocket and chain to secure them

10. Remove the cam sprocket and chain from the camshaft and leave on the slipper and damper.

    Fig. 9: Remove the cam sprocket and chain as an assembly

    NOTE: Be sure not to remove the slipper and damper. Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, follow the steps carefully.

11. To remove exhaust camshaft:
    1. Set the knock pin hole of the exhaust camshaft at the 5–30 degree BTDC of camshaft angle.

       NOTE: The above angle helps to lift the exhaust camshaft level and evenly by pushing No. 2 and No. 4 cylinder cam lobes of the exhaust camshaft to their valve lifters.

    2. Secure the exhaust camshaft sub-gear to main gear with a service bolt. The recommended size bolt is 0.63–0.79 inch (16–20mm) bolt length, 6mm thread diameter and 1.0mm thread pitch.

       NOTE: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the previous step.

    3. Uniformly loosen the 8 bolts on the No. 1, No. 2, No. 3 and No. 5 bearing caps in several passes in the proper sequence.

       NOTE: Do not remove No. 4 bearing cap bolt at this stage.

    4. Remove the No. 1, No. 2, No. 3 and No. 5 bearing caps.
    5. Alternately loosen No. 4 bearing cap. As No. 4 bearing cap bolts are loosened, check that the camshaft is being lifted out straight and level.

       NOTE: If the camshaft is not being lifted out straight and level, retighten the 2 No. 4 bearing cap bolts. Repeat steps, in order, (e) to (a) and reset the knock pin hole of the exhaust camshaft at 5–30°BTDC, then repeat steps (b) to (e) again. Do not pry or attempt to force the camshaft with a tool or another object.

    6. Remove the No. 4 bearing cap and exhaust camshaft.

       Fig. 10: Set knock pin hole of exhaust camshaft at 5–30 degrees BTDC of camshaft angle

       Fig. 11: Secure exhaust camshaft sub-gear to main gear with service bolt

       Fig. 12: A service bolt should be the correct size to fit in the hole of the gear

       Fig. 13: Remove No. 1, 2, 3 and 5 bearing caps (exhaust camshaft) in sequence shown

       Fig. 14: Loosening the No. 3 exhaust camshaft bearing cap bolts

       Fig. 15: Removing the No. 1 exhaust camshaft bearing

       Fig. 16: Alternately loosen and remove the bolts on the No. 4 bearing cap last

       Fig. 17: The No. 4 exhaust camshaft bearing is always removed last

       Fig. 18: Now the exhaust camshaft can be pulled out of the head

       NOTE: Remeber, the head is on the engine sideways and the camshaft can fall out if you are not careful. Hold on to the camshaft while removing the No. 4 bearing.

12. To remove the intake camshaft:
    1. Set the knock pin hole of the intake camshaft at the 75–100 degree BTDC of camshaft angle.

       NOTE: The above angle allows the no. 1 and No. 3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

    2. Uniformly loosen the 8 bolts on the No. 1, No. 2, No. 4 and No. 5 bearing caps in several passes in the proper sequence.

       NOTE: Do not remove No. 3 bearing cap bolt at this stage.

    3. Remove the No. 1, No. 2, No. 4 and No. 5 bearing caps.
    4. Alternately loosen No. 3 bearing cap. As No. 3 bearing cap bolts are loosened, check that the camshaft is being lifted out straight and level.

       NOTE: If the camshaft is not being lifted out straight and level, retighten the 2 No. 3 bearing cap bolts. Repeat step, in order from (d) to (a) and reset the knock pin of the intake camshaft at 75–100°BTDC, and repeat steps in order from (b) to (d) once again. Do not pry or attempt to force the camshaft with a tool or other object.

    5. Remove the No. 3 bearing cap and the intake camshaft.

       Fig. 19: Set knock pin of intake camshaft at 75–100 degrees BTDC of camshaft angle

       Fig. 20: Remove No. 1, 2, 4 and 5 bearing caps (intake camshaft) in sequence shown

       Fig. 21: Uniformly loosen and remove the intake camshaft bearing cap bolts

       Fig. 22: Remove the No. 3 intake camshaft bearing cap last

       Fig. 23: The intake camshaft can fall out if not grabbed quickly

13. Remove the valve lifters from the engine. Keep the shims and the lifters together. The lifters and the shims must be reinstalled in their original location.

    Fig. 24: Remove the lifters and shims together from the cylinder head

    Fig. 25: The shims and lifters are located in the head

    To install:

    NOTE: If any of the bolts break, deform or do not meet the tighten specification replace them.

14. Install the valve lifters and shims.
15. Install the intake camshaft:
    1. Apply MP grease to the thrust portion of the intake camshaft.
    2. Place the intake camshaft at 75–100 degrees BTDC. Install the bearing caps with the marking arrows facing forward. Uniformly tighten the bearing cap bolts in several passes in the proper sequence to 12 ft. lbs. (16 Nm).

       Fig. 26: Place the intake camshaft at 75–100°BTDC of the camshaft angle on the head

       Fig. 27: Camshaft bearing cap bolts tightening sequence; intake and exhaust are the same

16. Install the exhaust camshaft:
    1. Set the knock pin of the intake camshaft at 5–30 degrees BTDC of camshaft angle.
    2. Apply MP grease to the thrust portion of the exhaust camshaft.
    3. Engage the exhaust camshaft gear to the intake camshaft gear by matching the installation marks (timing marks).
    4. Roll down the exhaust camshaft onto the bearing journals while engaging the gears with each other. Make sure the exhaust and intake camshaft gear alignment marks are facing each other. The one gear has 2 dots and the other has 1 dot.
    5. Install the bearing caps with the marking arrows facing forward.
    6. Uniformly tighten the bearing cap bolts in several passes in the proper sequence to 12 ft. lbs. (16 Nm).

       Fig. 28: Set the knock pin of the intake camshaft at 5–30°BTDC of the camshaft angle

       Fig. 29: Engage the exhaust and intake camshafts by matching the timing marks to each gear

       Fig. 30: Install and uniformly tighten the 10 bearing cap bolts in several passes in this sequence

17. Apply sealer to the bottom of No. 6 bearing cap and install. Tighten the cap to 12 ft. lbs. (16 Nm).

    Fig. 31: Apply adhesive to the No. 6 bearing cap

18. Install the camshaft sprocket and chain. Hold the camshaft with a wrench and tighten the bolt to 54 ft. lbs. (74 Nm).

    Fig. 32: Retain the camshaft and tighten the bolt

19. Release the chain tensioner ratchet pawl. Fully push in the plunger and apply the hook to the pin so the plunger can not spring out and install the tensioner. Tighten the bolts to 15 ft. lbs. (21 Nm).

    Fig. 33: The tensioner has a hook to hold the plunger in the down position

    Fig. 34: Push the plunger in and position the hook over the pin

20. Set the tensioner: Turn the crankshaft to the left so the hook of the tensioner is released from the pin. If it does not spring out, press the slipper into the tensioner to release the hook.
21. Adjust the valve clearance.
22. Apply sealant 08826–00080 or equivalent to the cylinder head. Install the 2 half-circular plugs to the cylinder head and install the valve cover. Tighten the bolts to 69 inch lbs. (8 Nm).
23. Install the PCV hose.
24. Install the distributor.
25. Install the No. 2 cylinder head cover.
26. Install the engine wire and connect all connectors.
27. Install the engine/transmission assembly into the vehicle.
28. Fill the cooling system. Fill the engine with oil.
29. Connect the battery cable. Start the engine and check for leaks.
30. Road test the vehicle for proper operation. Recheck all fluid levels.