Camshaft and Valve Tappet

REMOVAL & INSTALLATION

1.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable.
   • Power steering hose brackets from the cylinder head cover
   • Spark plug wires and plug wire clips

     Fig. 1: Exploded view of the camshaft assemblies — 1.5L engine

   • Breather tube and Positive Crankcase Ventilation (PCV) valve from the cylinder head cover
   • Cylinder head cover by loosening in 2–3 steps
   • Accessory drive belts
   • Water pump pulley
   • Timing belt covers
   • Timing belt
   • Distributor
   • Camshaft sprocket bolts by holding the camshaft with a wrench on the cast hexagon
   • Camshaft sprockets

     Fig. 2: Front camshaft cap bolt loosening sequence — 1.5L engine

     Fig. 3: Camshaft cap bolt loosening sequence — 1.5L engine

   • Seal plate
3. Rotate the camshafts clockwise so the cams don't press on the tappets
4. Loosen the front camshaft cap bolts in 5–6 steps, starting on the 2 outside bolts and finishing on the 2 inside bolts.
5. Remove or disconnect the following:
   • Front camshaft bolts and caps

   NOTE: Note the location of the numbers on top of the camshaft caps, so the caps can be reinstalled in their original positions.

   • Camshaft cap bolts in 5–6 steps
   • Camshaft caps
   • Camshafts
   • Chain and oil seals from the camshafts
   • Lifters and adjustment shims, if necessary

   NOTE: Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

   To install:

6. Install or connect the following:
   • Lifters in their original positions, lubricated with engine oil.

   NOTE: Verify that they move smoothly in their bore.

   • Chain adjuster between the camshafts
   • Camshafts by lubricating the camshaft lobes and journals with engine oil

   NOTE: Be sure none of the lobes are located directly on the tappets.

7. Align the camshaft gear and timing chain marks.

   Fig. 4: When installing the camshafts, align the marks on the camshaft gears with the colored/marked links of the chain — 1.5L engine

   Fig. 5: Apply sealant in the positions shown before installing the camshaft bearing caps — 1.5L engine

   Fig. 6: Tighten the camshaft cap bolts according to the sequence shown — 1.5L engine

8. Apply silicone sealant to the cylinder head on the front camshaft caps mating surface. Do not get sealant on the camshaft journals.
9. Install the camshaft bearing caps in their original locations.
10. Hand-tighten the camshaft cap bolts numbered: 5, 7, 2 and 4. Tighten, in sequence, in 5–6 steps with a final torque of 100–125 inch lbs. (11–14 Nm).
11. Install or connect the following:
    • New camshafts seals lubricated with engine oil, using a seal installer until the seals are flush with the edge of the camshaft cap
    • Seal plate
    • Camshaft sprockets
    • Timing belt and timing belt covers
    • Water pump pulley
    • Accessory drive belts
12. Adjust the drive belt tension.
13. Apply silicone sealant to a new cylinder head cover gasket, and install the gasket on the cylinder head cover.
14. Apply silicone sealant to the cylinder head in the area adjacent to the front camshaft caps.
15. Install or connect the following:
    • Distributor
    • Cylinder head cover. Tighten the bolts in 2 steps, by reversing of the loosening sequence, to 61–95 inch lbs. (7–11 Nm).
    • Power steering hose brackets. Tighten the bolts to 88 inch lbs. (10 Nm).
    • Spark plug wires and clips
    • Breather hose and PCV valve
    • Adjust the valve clearance

1.6L, 1.8L and 2.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   • Negative battery cable
   • Spark plug wires
   • Spark plugs

     Fig. 7: Camshaft cap bolt loosening sequence — 1.8L (BP) and 2.0L engines

     Fig. 8: Camshaft cap bolt loosening sequence — 1.6L and 1.8L (FP) engines

   • Cylinder head cover hoses, if equipped
   • Cylinder head cover bolts
   • Cylinder head cover
   • Timing belt
   • Distributor
   • Camshaft by holding it with a wrench on the hexagon cast into the camshaft
   • Sprocket bolts
   • Sprockets

   NOTE: Label the caps so they can be reinstalled in their original positions.

   • Camshaft cap bolts by loosening in 2–3 steps in the sequence shown.
   • Camshaft caps
   • Lifters and adjustment shims, if necessary

   NOTE: Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

   To install:

3. Install or connect the following:
   • Lifters in their original positions by lubricating them with engine oil

   NOTE: Verify that they move smoothly in their bore.

   • Camshafts by lubricating the journals and lobes with clean engine oil

     Fig. 9: Apply silicone sealant to the cylinder head in the positions shown — 1.8L (BP) and 2.0L engines

     Fig. 10: Apply silicone sealant to the cylinder head in the positions shown — 1.6L and 1.8L (FP) engines

     Fig. 11: Camshaft cap bolt tightening sequence — 1.8L (BP) and 2.0L engines

     Fig. 12: Camshaft cap bolt tightening sequence — 1.6L and 1.8L (FP) engines

4. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
5. Install or connect the following:
   • Camshaft caps in their original positions
   • Cap bolts. Tighten the bolts in 2–3 steps to 125 inch lbs. (14 Nm) in the proper sequence.
   • New camshaft seal by lubricating it with engine oil. Tap the seal into position, using a seal installer, until it is flush with the edge of the camshaft cap on 1.8L (BP) and 2.0L engines or recessed into the cylinder head 0.012–0.027 in. (0.3–0.7mm) on the 1.6L and 1.8L (FP) engine.
6. Turn the camshafts until the dowel pins face straight up.
7. Install or connect the following:
   • Camshaft sprockets. Tighten the bolts to 44 ft. lbs. (60 Nm) by holding the camshaft with the wrench on the cast hexagon.
   • Remaining components

2.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Timing belt covers and timing belt
   • Spacer and O-ring from the front of the camshaft
   • Ignition coils
   • Intake manifold
   • Cylinder head cover bolts, in 5–6 steps, by reversing of the tightening sequence.
   • Cylinder head cover
   • Camshaft sprockets
4. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the adjustment shims.
5. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right-hand (rear) caps are marked with numbers and the left-hand (front) caps are marked with letters.
6. Remove or disconnect the following:
   • Front camshaft caps by reversing of the torque sequence, in 5–6 steps
   • Remaining camshaft caps using the proper sequence

   NOTE: Remove the thrust caps last. Do not damage the cylinder head thrust bearing support.

   • Camshafts and oil seals
   • Lifters and adjustment shims, if necessary.

   NOTE: Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

   To install:

7. Install or connect the following:
   • Lifters in their original positions, lubricated with engine oil. Verify that they move smoothly in their bore.
   • New oil seals on the camshafts
   • Camshafts with the camshaft lobes, journals and supports lubricated with engine oil and the gear marks aligned
   • Thrust caps. Tighten the bolts, in 5–6 steps, until the caps are fully seated on the cylinder head
8. Apply silicone sealant, at a thickness of 0.06–0.09 in. (1.5–2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity.
9. Install or connect the following:
   • Remaining camshaft caps in their original positions. Tighten the bolts, in sequence, in 5 equal steps, with the final step being 100–125 inch lbs. (11–14 Nm).
   • New camshaft oil seal lubricated with engine oil. Tap the seal in evenly with a Seal Installer tool 49 F401 337A with a final protrusion of 0–0.02 in. (0–0.5mm).
   • New blind cap by tapping it in.
   • Camshaft sprockets. Tighten the bolts to 91–103 ft. lbs. (123–140 Nm).
10. Measure and adjust valve clearances.
11. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
12. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps.
13. Install or connect the following:
    • New gasket on the cylinder head
    • Cylinder head cover. Tighten the cover bolts in 5–6 steps, in sequence, to 44–78 inch lbs. (5–9 Nm).
    • Distributor using a new O-ring
    • Ignition coils
    • Intake manifold
    • Spacer using a new O-ring. Tighten the bolt to 14–18 ft. lbs. (19–25 Nm).
    • Timing belt and timing belt cover
    • Negative battery cable
14. Run the engine and check for leaks.

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Drain the cooling system
5. Remove or disconnect the following:
   • Timing belt
   • Accelerator cable
   • Spark plug wires
   • Necessary wiring and hoses
   • Intake manifold
   • Cylinder head covers
   • Distributor
   • Camshaft sprocket bolt by holding the camshaft with a wrench on the hexagon cast into the camshaft
   • Camshaft Sprocket

     Fig. 13: Front camshaft cap bolt loosening sequence — 2.3L and 2.5L engines

     Fig. 14: Camshaft cap bolt loosening sequence — 2.3L and 2.5L engines

6. Turn the camshaft, using a wrench on the cast hexagon, until the camshaft knock pin is aligned with the cylinder head marks.

   NOTE: Do not remove the camshaft caps when the camshaft lobe is pressing on a lifter, as the thrust journal support may become damaged.

7. Loosen the front camshaft cap bolts in 5–6 steps, in the proper sequence. Bolt A is only on the right cylinder head. Remove the front camshaft cap.
8. Mark the position of the camshaft caps so they can be reinstalled in their original locations. Loosen the remaining camshaft cap bolts in 5–6 steps, in the proper sequence, then remove the caps.
9. Remove or disconnect the following:
   • Camshafts
   • Lifters and adjustment shims, if necessary

   NOTE: Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

   To install:

10. Install or connect the following:
    • Lifters in their original positions lubricated with engine oil. Verify that they move smoothly in their bore.
    • Camshafts by lubricating the camshaft journals, lobes and gears with clean engine oil and aligning the timing marks

    NOTE: The thrust plate positions for the right and left cylinder head camshafts are different.

    Fig. 15: When installing the camshafts, ensure that the marks on the cam gears are aligned — 2.3L and 2.5L engines

    Fig. 16: Put silicone sealant on the cylinder head at the positions shown — 2.3L and 2.5L engines

    Fig. 17: Front camshaft cap bolt tightening sequence — 2.3L and 2.5L engines

    Fig. 18: Camshaft cap bolt tightening sequence — 2.3L and 2.5L engines

11. Be sure the camshaft cap and cylinder head surfaces are clean. Apply a small amount of sealant to the mating surface of the front camshaft cap on both cylinder heads and the rear exhaust camshaft cap on the left cylinder head. Do not get any sealant on the camshaft rotating surfaces.
12. Install or connect the following:
    • Front camshaft caps and thrust plate caps. Tighten the bolts until the cap seats fully to the cylinder head
    • Remaining caps in their original locations. Tighten the bolts in 5–6 steps to 126 inch lbs. (14 Nm), in the proper sequence.
    • New oil seals in the cylinder head using an installer
    • New blind cap coated with sealant, tap it in place using a plastic hammer
    • Camshaft sprockets

    NOTE: On the right cylinder head, install the sprocket so the R mark can be seen and the timing mark aligns with the camshaft knock pin. On the left cylinder head, install the sprocket so the L mark can be seen and the timing mark aligns with the camshaft knock pin.

13. Camshaft sprocket bolts lubricated with engine oil, by holding the camshaft with a wrench on the cast hexagon. Tighten the bolt to 103 ft. lbs. (140 Nm).
14. Cylinder head cover using a new gasket coated with sealant. Tighten the bolts, in sequence, in 2–3 steps, to 78 inch lbs. (8.8 Nm).
15. Ventilation pipe to the left cover
16. Distributor using a new O-ring lubricated with engine oil
17. Distributor with the blade fitting into the camshaft groove and loosely tighten the retaining bolt.
18. Intake manifold, using a new gasket, loosely tighten the bolts.
19. Instake manifold stay. Tighten the bolts to 19 ft. lbs. (25 Nm).
20. Intake manifold bolts/nuts. Tighten them, in 2–3 steps, to 19 ft. lbs. (25 Nm).
21. Wiring, hoses and fuel lines
22. Accelerator cable
23. Throttle valve cables, if equipped
24. Timing belt
25. Negative battery cable
26. Fill the cooling system.
27. Start the engine and check for leaks.