Camshaft: Service and Repair

1. Remove timing belt and related components.
2. Disconnect cam angle sensor and ignition coil connectors.
3. Remove cam angle sensor and bracket, then fully loosen ignition coil mounting bolts.
4. Disconnect blow-by hose, then remove cylinder head cover and gasket.
5. Remove front camshaft cap, camshaft oil seal and plug.
6. Remove intake and exhaust camshafts as follows:
a. On lefthand side camshafts, rotate intake camshaft (upper) and exhaust camshaft (lower) so notch at front end of each camshaft faces directly downward.
b. On righthand side camshafts, rotate intake camshaft (upper) and exhaust camshaft (lower) so notch at front end of each camshaft faces directly upward.
c. On either side, looking from rear side of camshaft gears, ensure match marks on gears are aligned.

Fig. 43 Securing Camshaft:

d. Install .24 in diameter bolt to sub-gear mounting bolt hole of intake camshaft gear to secure gear train, Fig. 43.

Fig. 44 Intake Camshaft Removal Sequence:

e. Loosen bolts on intake camshaft caps equally, a little at a time, in sequence shown in Fig. 44. Ensure as bolts are loosened, clearance between camshaft journal and cylinder head journal bearing increases evenly. If not, tighten bolts by reversing sequence in Fig. 44, and repeat this step.
f. Remove camshaft caps while holding intake camshaft, then remove camshaft. If intake camshaft is hard to remove, rotate exhaust camshaft counterclockwise.
g. Arrange caps in correct order. Caps must be installed in their original positions.

Fig. 45 Exhaust Camshaft Removal Sequence:

h. Loosen bolts on exhaust camshaft caps equally, a little at a time, in sequence shown in Fig. 45. Ensure as bolts are loosened, clearance between camshaft journal and cylinder head journal bearing increases evenly. If not, tighten bolts by reversing sequence in Fig. 45, and repeat this step.
i. Remove camshaft caps while holding exhaust camshaft, then remove camshaft. Arrange caps in correct order. Caps must be installed in their original positions.
7. Remove hydraulic lash adjuster. Arrange adjusters in correct order. Adjusters must be installed in their original positions.
8. Service intake camshaft as follows:
a. Using a rag, secure shaft portion of camshaft in vice, then remove bolt installed in sub-gear.
b. Using camshaft gear wrench No. 49920-7200 or equivalent, turn sub-gear clockwise, then remove snap ring.
c. Remove wave washer, sub-gear and gear spring.
d. Reverse step 8 to assembly intake camshaft.
9. Install exhaust camshaft as follows:
a. Install lash adjusters. Apply coat of clean engine oil to adjuster surface.
b. Apply coat of clean engine oil to camshaft journals.
c. Set exhaust camshaft on cylinder head with front end notch of camshaft facing directly downward.
d. Attach camshaft caps in their original positions. Fully hand tighten cap bolts.

Fig. 46 Exhaust Camshaft Installation Sequence:

e. Tighten cap bolts equally, a little at a time, in sequence shown in Fig. 46, to specifications. Ensure as bolts are tightened, clearance between camshaft journal and cylinder head journal bearing decreases evenly. If not, loosen bolts by reversing sequence in Fig. 46, and repeat this step.
10. Install intake camshaft as follows:
a. Install lash adjusters. Apply coat of clean engine oil to adjuster surface.
b. Apply coat of clean engine oil to camshaft journals.

Fig. 47 Camshaft Match Mark Alignment:

c. On lefthand side camshafts, align intake camshaft match mark with match mark of exhaust camshaft. Ensure notch on front end of camshafts are facing same direction (downward), Fig. 47.
d. On righthand side camshafts, align intake camshaft match mark with match mark of exhaust camshaft. Ensure notch on front end of camshafts are facing same direction (upward), Fig. 47.
e. On either side, attach camshaft caps in their original positions. Fully hand tighten cap bolts. Ensure match marks on rear side of camshaft gears are aligned.

Fig. 48 Intake Camshaft Installation Sequence:

f. Tighten cap bolts equally, a little at a time, in sequence shown in Fig. 48, to specifications. Ensure as bolts are tightened, clearance between camshaft journal and cylinder head journal bearing decreases evenly. If not, loosen bolts by reversing sequence in Fig. 48, and repeat this step.
11. Remove sub-gear securing bolt from intake camshaft gear.
12. Apply fluid packing for mating surface of front camshaft cover, then install camshaft cover.
13. Using oil seal guide No. 49959-7000 and oil seal installer No. 49958-7300 or equivalents, lubricate and install new camshaft oil seal.
14. Using plug installer No. 49803-7100 or equivalent, install camshaft plug.

Fig. 49 Cylinder Head Cover Lube Points:

15. On lefthand side camshafts, install cylinder head cover. Apply soapy water over A and B shown in Fig. 49.
16. On righthand side camshafts, install cylinder head cover. Apply soapy water over A shown in Fig. 49.
17. On either side, connect blow-by hose, then install ignition coils and cam angle sensor.