Let there be light....but no pics
Camshaft Removal and Installation Guide:
Both camshafts have six bearing journal surfaces and two cam lobes per cylinder. Flanges at the rear journals control camshaft endplay. Provision for a cam position sensor is located on the intake camshaft on the rear of the cylinder head. A hydrodynamic oil seal is used for oil control at the front of the camshaft
-Camshaft Operation- The camshaft is driven by the crankshaft via drive sprockets and belt. The camshaft has precisely machined lobes to provide accurate valve timing and duration.
Removal Of Stock Cams:
Removing the stock cams will require you to remove the cylinder head cover, camshaft position sensor, timing belt, camshaft sprockets, timing belt rear cover, upper & lower timing belt covers, and any components attached to these.
Removal Of The Cylinder Head Cover-
1. Disconnect the negative battery cable (safety precaution)
2. Disconnect ignition coil connector.
3. Disconnect spark plug wires and remove ignition coil.
4. Disconnect PCV and make-up air hoses from the cylinder head cover.
5. Unclip wiring harness from cylinder head cover studs.
6. Remove nut securing coolant return line bracket to cylinder head cover stud.
7. Remove cylinder head cover fasteners.
8. Remove cylinder head cover from cylinder head.
Now you are going to remove the camshaft position sensor and camshaft target magnet (As with any other sensor use extreme caution when handling with these. Sensor are very delicate and my be expensive if you have to replace them)
Description of the Camshaft Position Sensor - The camshaft position sensor attaches to the rear of the cylinder head. The PCM determines fuel injection synchronization and cylinder identification from inputs provided by the camshaft position sensor and the crankshaft position sensor. From the two inputs, the PCM determines crankshaft position.
Removal of the Camshaft Position Sensor -
The camshaft position sensor is mounted to the rear of the cylinder head. It will be near the battery. Some aftermarket intakes are close to this sensor.
1. Remove brake booster hose and electrical connector from holders on end of cylinder head cover and reposition.
2. Disconnect electrical connectors from camshaft position sensor.
3. Remove camshaft position sensor mounting screws. Remove sensor.
Now you are going to want to remove the upper and lower timing belt covers. This can be a little time consuming due to the limited amount of space. Just take you time and don't get frustrated.
Removal of the Upper Front Cover -
1. Remove upper torque strut mount (motor mount as some may know it)
2. Remove torque strut bracket from strut tower.
3. Remove torque strut bracket from engine.
4. Remove upper timing belt cover fasteners and remove cover. (There will be three fasteners that hold the upper cover)
Removal of the Lower Front Cover - When removing the lower front cover it will require removing other item while in the process.
1. Raise the car and remove the right front wheel.
2. Remove the accessory drive belt splash shield that is located under the car below the intercooler pipe.
3. At this time you are now going to remove the accessory drive belts. This is a new process;
Removal of Drive Belts - There are going to be two belts that you remove. One is the Power Steering Pump and the Air Conditioning Compressor Belt, and the Alternator Belt. Word of advice, if your car is about 10 months old go ahead and buy new belts. They are cheap and you will have to do it sooner or later.
Power Steering Pump and Air Conditioning Compressor Belt -
1. Using a 17 mm wrench, rotate belt tensioner clockwise until belt can be removed from power steering pump pulley. Gently, release spring tension on tensioner.
2. Remove the belt.
Alternator Belt - (You must remove the power steering pump and air conditioning compressor belt before this can be removed)
1. Loosen alternator locking nut. (This is located above the alternator)
2. Raise front of car.
3. Remove accessory drive belt splash shield if you haven't done so yet.
4. Loosen alternator pivot bolt. (This is located below the alternator)
5. Loosen alternator adjusting bolt until alternator belt can be removed.
6. Remove generator belt.
Continued from Removal of the Lower Front Cover -
4. At this time you are now going to remove the crankshaft damper. This is a new process;
Removal of Vibration Damper - This pulley is located on the side where the belts are on the bottom above the oil pan. You will need two special tools to take this off. You can purchase this at the local dealership; Special Tool 1026 and Insert 6827A. It may not be necessary to remove this.
1. Accessory drive must be removed if not done so yet.
2. Remove crankshaft damper bolt.
3. Remove damper by using Special Tool 1026 and Insert 6827A.
Continued from Removal of the Lower Front Cover -
5. At this time you are now going to remove the lower torque strut. This is a new process;
Removal of the Lower Torque Strut (or lower torque mount) -
1. Remove the accessory drive belt splash shield if you have not done so already.
2. Remove pencil strut. (This is attached to the frame then to the lower torque strut. One end is closed, the other end is open)
3. Remove the bolts attaching the lower torque strut to cross member and strut bracket.
4. Remove lower torque strut.
Continued from Removal of the Lower Front Cover -
6. Disconnect A/C pressure switch at rear of compressor housing.
7. Lower car and support engine with a jack.
8. Remove upper torque strut attaching bolts and remove strut. (This will be the upper torque mount)
9. Remove power steering pump and bracket. Set pump aside. DO NOT DISCONNECT LINES FROM PUMP.
10. With engine properly supported, remove right engine mount through bolt.
11. Raise engine properly supported, and remove right engine mount though bolt.
12. At this time you will be able to remove the timing belt cover fasteners and remove cover
Now you will begin the process of removing the timing belt and sprockets.
Removal of the Timing Belt -
1. After removing the Timing Belt Covers you will not begin removing the Timing Belt.
NOTE: WHEN ALIGNING CRANKSHAFT AND CAMSHAFT TIMING MARKS ALWAYS ROTATE ENGINE FROM CRANKSHAFT. CAMSHAFT SHOULD NOT BE ROTATED AFTER TIMING BELT IS REMOVED. DAMAGED TO VALVE COMPONETS MAY OCCUR. ALWAYS ALIGN TIMING MARKS BEFORE REMOVING TIMING BELT.
2. Before removing the timing belt, rotate crankshaft until the TDC (Top Dead Center) mark on oil pump housing aligns with the TDC mark on crankshaft sprocket.
NOTE: THE CRANKSHAFT SPROCKET TDC MARK IS LOCATED ON THE TRAILING EDGE OF THE SPROCKET TOOTH. FAILURE TO ALIGN TRAILING EDGE OF SPROCKET TOOTH TO TDC MARK ON OIL PUMP HOUSING WILL CAUSE THE CAMSHAFT TIMING MARKS TO BE MISALIGNED.
3. Loosen timing belt tensioner lock bolt.
4. Insert a 6 mm Allen wrench into the hexagon opening located on the top plate of the belt tensioner pulley. Rotate the top place CLOCKWISE until there is enough slack in timing belt to allow for removal.
6. Now after all this, remove the timing belt.
Ok now you are going to remove the camshaft sprockets.
Removal of the Camshaft Sprockets -
1. Using a special camshaft sprocket holder remove the sprocket bolts.
2. Remove camshaft sprockets.
All most done not too much more. You are now going to remove the timing belt rear cover.
Removal of the Timing Belt Rear Cover -
1. Remove timing belt idler pulley.
2. Now remove timing belt cover fasteners and remove cover from engine.
With the cylinder head cover removed you are now going to remove the bearing caps. These caps are what hold the camshafts in place. The bearing caps are identified for location.
Removal of the Bearing Caps -
1. Remove the outside bearing caps first.
2. Loosen the camshaft bearing cap attaching fasteners in sequence shown one camshaft at a time. Make sure keep in the same exact order!
NOTE: CAMSHAFTS ARE NOT INTERCHANGEABLE. THE INTAKE CAM NUMBER 6 THRUST BEARING FACE SPACING IS WIDER.
Removing of the Camshafts -
At this time you will be able to lift the cams from the head.
Congratulation you have successfully completed the removal. Yeap, now you got to put the other back in. Ok . . . here we go . . .
Camshaft Installation
At this time since you have your car in pieces now maybe a good time to look for abnormal wear. Few place to check are the camshaft bearing journals for damage and binding. If journals are binding, check the cylinder head for damage. Also check cylinder head oil holes for flogging. Now with new camshaft in hand you are ready.
NOTE: ENSURE THAT NONE OF THE PISTONS ARE AT TOP DEAD CENTER WHEN INSTALLING THE CAMSHAFTS.
Installation of the Camshafts -
1. Lubricate all camshaft bearing journals, rocker arms and camshaft lobes.
2. Position camshafts on cylinder head bearing journals. Install right and left camshaft bearing caps. Number 2 - 5 and right Number 6. Tighten M6 fasteners to 105 in.lbs. in this sequence:
Camshaft 1
7--1--3--5--9
8--2--4--6--10
Camshaft 2
7--1--3--5
8--2--4--6
3. Apply a gasket maker to Number 1 and Number 6 bearing caps and tighten M8 fasteners to 250 in.lbs.
NOTE: BEARING END CAPS MUST BE INSTALLED BEFORE SEALS CAN BE INSTALLED.
4. Install the camshaft target magnet and camshaft position sensor.
5. At this time you are now going to install the cylinder head cover. This is a new process;
Installation of the Cylinder Head Cover -
Note: DO NOT ALLOW OIL TO CONTACT THE TIMING BELST AS IT MAY CAUSE DETERIORATES THE RUBBER AND CAUSE TOOTH SKIPPING.
1. Clean the cylinder head cover sealing surface.
2. Install new cylinder head cover gasket and spark plug well seals.
3. Apply RTV at the camshaft cap corners and at the top edges of the 1/2 round seal.
4. Install cylinder head cover assembly to cylinder head. Install all fasteners, ensuring the double ended studs are in their proper location. Tighten fasteners in sequence:
6--2--7
4--1--5
8--3--9
Now using a 3 step torque methods torque as follows:
First tighten all bolts to 40 in.lbs.
Now tighten all bolts to 80 in.lbs.
Last tighten all bolts to 105 in.lbs.
5. Install nut securing coolant return line bracket to cylinder head cover stud.
6. Clip wiring harness to cylinder head cover studs.
7. Install ignition coil and connect spark plug wires. Tighten ignition coil fasteners to 105 in.lbs.
8. Connect ignition coil connector.
9. Connect the PCV and make-up air hoses to cylinder head cover.
10 Connect negative battery cable.
Continued from Installation of Camshafts -
6. At this time you are now going to install the timing belt rear cover. This is a new process;
Installation of the Timing Rear Cover -
1. Install rear timing belt cover and fasteners. Torque fasteners:
M6 Bolts - 105 in.lbs.
M8 Bolts - 250 in.lbs.
2. Install timing belt idler pulley. Torque pulley fastener to 45 ft.lbs.
3. Install camshaft sprockets. Using special camshaft sprocket tool hold sprockets with tool while tightening center bolt to 85 ft.lbs.
NOTE: DO NOT USE AN IMPACT WRENCH TO TIGHTEN CAMSHAFT SPROCKET BOLTS. DAMAGE TO THE CAMSHAFT-TO-SPROCKET LOCATING DOWEL PIN MAY OCCUR.
Continued from Installation of Camshafts -
7. At this time you are now going to install the timing belt. This is a new process;
Installation of the Timing Belt -
1. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.
2. Set camshafts timing marks so that the exhaust camshaft sprocket is a 1/2 notch below the intake camshaft sprocket.
3. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner.
4. Move the exhaust camshaft sprocket counterclockwise to align marks and take up belt slack.
5. Insert a 6 mm Allen wrench into the hexagon opening located on the top ;late of the belt tensioner pulley. Rotate the top plate COUNTERCLOCKWISE. The tensioner pulley will move against the belt and the tensioner setting notch will eventually start to move clockwise. Watching the movement of the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang. Using the Allen wrench to prevent the top plate from moving, torque the tensioner lock bolt to 220 in.lbs. Setting notch and spring tang should remain aligned after lock bolt is torque.
6. Remove Allen wrench and torque wrench.
7. Rotate the crankshaft CLOCKWISE two complete revolutions manually for seating of the belt, until the crankshaft is repositioned at the TDC position. Verify that the camshaft and crankshaft timing marks are in proper position.
NOTE: REPOSITIONING THE CRANKSHAFT TO THE TDC POSITION MUST BE DONE ONLY DURING THE CLOCKWISE ROTATION MOVEMENT. IF TDC IS MISSED, ROTATE A FURTHER TWO REVOLUTIONS UNTIL TDC IS ACHIEVED. DO NOT, DO NOT ROTATE CRANKSHAFT COUNTERCLOCKWISE AS THIS WILL MAKE VERIFICATION OF PROPER TENSIONER SETTING IMPOSSIBLE.
8. Check if the spring tang is within the tolerance window. If the spring tang is within the tolerance window, the installation process is complete and nothing further is required. If the spring tang is not within the tolerance window, repeat Steps 5 through 7.
Continued from Installation of Camshafts -
8. At this time you are now going to install the upper & lower covers. This is a new process;
Installation of the Upper Front Cover -
1. Install timing belt cover and tighten fasteners to 50 in.lbs.
2. Install torque strut bracket to engine.
3. Install torque strut bracket to strut tower.
4. Install upper torque strut attaching bolts.
Installation of the Lower Front Cover -
1. Install lower timing belt cover and tighten fastenters to 50 in.lbs.
2. Install engine support bracket. Ensure the power steering pump is properly located in mounting location on bracket. Tighten mount bracket bolts to 45 ft.lbs.
3. Lower engine into mounting position and install right engine mount through bolt. Tighten bolt to 87 ft.lbs.
4. Install power steering pump and bracket.
5. Install upper torque strut attaching bolts
6. Raise car.
7. Connect A/C pressure switch connector
8. At this time you are now going to install the crankshaft damper. This is a new process;
Installation of the Crankshaft Damper -
1. Install crankshaft damper using the same special tool that was used to take the pulley off.
2. Tighten to 100 ft.lbs.
9. Now at this time you will install the accessory drive belts. This operation should be done in the reverse order as they were taken off.
10. Now install the lower torque mount.
11. Install accessory drive belt splash shield.
12. Install right front wheel.
Your all done now . . .
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