Camshaft: Service and Repair

Removal

1. Disconnect battery ground cable.
2. Drain coolant from engine block and radiator.
3. Remove suspension upper brace.
4. On models equipped with automatic transmission, disconnect transmission throttle valve cable and bracket from throttle body.
5. On all models, disconnect accelerator cable and bracket from throttle body.
6. Remove coolant reservoir tank, then cruise control actuator and bracket (if equipped).
7. Remove air cleaner assembly, air flow meter, air cleaner hose, alternator and alternator upper bracket.
8. Remove oil pressure gauge and engine hanger brackets.
9. Raise and support vehicle, then remove right front wheel and engine right side undercover.
10. Remove front suspension lower crossmember, then disconnect exhaust pipe from catalytic converter.
11. Disconnect oxygen sensor, then remove exhaust manifold heat insulator and manifold to cylinder head attaching bolts. Remove exhaust manifold/catalytic converter assembly.
12. Disconnect distributor connectors and high tension leads from spark plugs, then remove distributor assembly.
13. Remove coolant outlet and coolant bypass pipe from cylinder head.
14. Remove EGR valve and modulator, then the throttle body and cold start injector delivery pipe.
15. Remove air tube from intake manifold, then the intake manifold.
16. Remove fuel delivery pipe and injectors, then the spark plugs.
17. Remove timing belt and camshaft sprocket. Refer to TIMING BELT for procedure.
18. Remove timing belt rear cover from cylinder head.
19. Remove valve cover attaching nuts, grommets, valve cover and gasket. If grommets are to be reused, arrange them in order so they can be installed in the same position as removed.
20. Remove camshafts as follows: During removal, the camshafts must remain level with top of cylinder head. If camshafts are not kept level, cylinder head damage may result.

Fig. 1 Exhaust Camshaft Bearing Cap Bolts 1 & 2 Removal. 3S-FE:

Fig. 2 Exhaust Camshaft Bearing Cap Bolt 3 Through 8 Removal. 3S-FE:

Fig. 3 Exhaust Camshaft Bearing Cap Bolt 9 & 10 Removal. 3S-FE:

Fig. 4 Intake Camshaft Bearing Cap Bolt 1 & 2 Removal. 3S-FE:

a. Set intake camshaft sprocket lockpin at 10-45° BTDC of camshaft angle. With the intake cam set as above, the exhaust cam lobes will be applying pressure to cylinders Nos. 2 and 4 exhaust valve springs, which will aid in lifting and keeping camshaft level during removal.
b. Secure exhaust camshaft sub-gear to exhaust camshaft main gear with a service bolt. The bolt must have a thread pitch of 1.0mm, a thread diameter of 6mm and a length of 16-20mm. When removing camshaft, ensure torsional spring force of sub-gear has been eliminated by above operation.
c. Remove exhaust camshaft rear bearing cap bolts 1 and 2, Fig. 1, then the bearing cap.
d. Loosen bearing cap bolts 3 through 8 in small increments, following sequence, Fig. 2. Remove cap bolts and caps.
e. Alternately loosen and remove bearing cap bolts 9 and 10, Fig. 3. As bearing cap bolts 9 and 10 are being loosened, ensure camshaft is being lifted level and straight from the cylinder head. If camshaft is not being lifted level and straight from the cylinder head, tighten cap bolts 9 and 10, then reverse steps c and d above to install camshaft. Repeat steps a, c, d and e.
f. Remove bearing cap, then the exhaust camshaft.
g. Set intake camshaft sprocket lockpin at 80-115° BTDC of camshaft angle. With the intake cam set as above, the intake cam lobes will be applying pressure to cylinders Nos. 1 and 3 intake valve springs, which will aid in lifting and keeping camshaft level during removal.
h. Remove intake camshaft front bearing cap bolts 1 and 2, Fig. 4, then the bearing cap and oil seal. If the front bearing cap cannot be removed by hand, leave in position at this time.

Fig. 5 Intake Camshaft Bearing Cap Bolt 3 Through 8 Removal. 3S-FE:

Fig. 6 Intake Camshaft Bearing Cap Bolt 9 & 10 Removal. 3S-FE:

Fig. 7 Cylinder Head Bolt Loosening Sequence. 3S-FE:

i. Loosen bearing cap bolts 3 through 8 in small increments, following sequence, Fig. 5. Remove cap bolts and caps.
j. Alternately loosen and remove bearing cap bolts 9 and 10, Fig. 6. As bearing cap bolts 9 and 10 are being loosened, ensure camshaft is being lifted level and straight from the cylinder head. If camshaft is not being lifted level and straight from the cylinder head, tighten cap bolts 9 and 10, then reverse steps h and i above to install camshaft. Repeat step g, h and i.
k. Remove bearing cap, then the intake camshaft.
21. Loosen cylinder head bolts in small increments, following sequence, Fig. 7. If cylinder head bolt loosening sequence is not followed, head warpage or cracking could result.
22. Lift cylinder head from block and place on wooden blocks.

Installation

Fig. 8 Cylinder Head Bolt Tightening Sequence. 3S-FE:

1. Note installation directions, then place new gasket on engine block. Install cylinder head.
2. Lightly lubricate head bolts with clean engine oil and install.
3. Torque cylinder head bolts in several passes in sequence shown, Fig. 8, to 36 ft. lbs.
4. Mark front of each cylinder head bolt with paint, then tighten each bolt an additional 90° in sequence shown.

Fig. 9 Intake Camshaft Bearing Cap Bolt Tightening Sequence. 3S-FE:

Fig. 10 Intake & Exhaust Camshaft Alignment. 3S-FE:

Fig. 11 Exhaust Camshaft Bearing Cap Bolt Tightening Sequence. 3S-FE:

5. Install camshafts as follows: During installation, the camshafts must remain level with top of cylinder head. If camshafts are not kept level, cylinder head damage may result.
a. Apply multipurpose grease to intake camshaft thrust surface, then install camshaft with sprocket lockpin positioned at 80° BTDC.
b. Apply suitable seal packing to outer .08-.12 inch of No. 1 bearing cap mounting flange, then install bearing caps in positions removed from with arrows facing forward.
c. Lightly lubricate bearing cap bolts, then install and tighten in small increments to a final torque of 14 ft. lbs., following sequence, Fig. 9.
d. Apply multipurpose grease to intake camshaft oil seal lip, then install with suitable seal installer.
e. Rotate intake camshaft as necessary to position sprocket lockpin at 10° BTDC, then apply multipurpose grease to exhaust camshaft thrust surface.
f. Engage exhaust camshaft gear to intake camshaft gear by aligning timing marks, Fig. 10, then rolling exhaust camshaft into bearing journals while maintaining gear engagement. Camshaft gears have two sets of timing marks. Do not use the assembly reference marks, Fig. 10.
g. Rotate intake camshaft as necessary until exhaust camshaft is seated evenly in bearing journals.
h. Install bearing caps in positions removed from with arrows facing forward.
i. Lightly lubricate bearing cap bolts, then install and tighten in small increments to a final torque of 14 ft. lbs., following sequence, Fig. 11.
6. Remove service bolt from exhaust camshaft main and sub-gear assembly.
7. Reverse steps 1 through 19 to complete installation. After installation is complete, adjust valves. Refer to Engine/Cylinder Head Assembly/Valve, Intake/Exhaust/Adjustments for procedure.
8. Check and adjust ignition timing and toe-in as necessary.