Camshaft: Service and Repair

Camshaft and Valve Rocker
Removal
1. Removing distributor
(a) Disconnect spark plug cords from distributor.
(b) Remove distributor by removing mounting bolts.
2. Remove timing belt, belt cover and related parts. (Refer to "Timing Belt and Belt Cover".) Service and Repair
3. Remove water pipe.
4. Remove oil filler duct.
5. Remove PCV hoses from rocker cover.






6. Remove EGR pipe cover, pipe clamps and EGR pipe. [TURBO MODEL]
7. Remove valve rocker covers and gaskets.
8. Remove camshaft cases, camshaft support, and camshaft as a unit.






When removing camshaft case, valve rockers may come off. To prevent them from being damaged, be sure to place waste cloth or rubber mat under cylinder head. Remove valve lash adjusters from cylinder head.






(a) Do not lay down removed adjusters; keep them erect.
(b) Retain removed valve rockers and adjusters in the order of their removal so that they can be reinstalled correctly.
DISASSEMBLY
1. Remove camshaft support.






2. Remove camshaft.






3. Remove oil relief plug, then remove oil relief pipe, relief valve spring, and relief valve.
CAMSHAFT






1. Measure the bend, and repair or replace if necessary.
Limit: 0.025 mm (0.0010 in).






2. Check journal for damage and wear. Replace If faulty.











3. Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded.
4. Measure backlash between distributor drive gear and distributor driven gear. If the limit is exceeded, replace distributor drive gear.
Backlash:
Standard: 0.015 - 0.126 mm (0.0006 - 0.0050 in).
Limit: 0.180 mm (0.0071 in).
5. Replace gear using a press and CAMSHAFT HOLDER (498027000).
VALVE ROCKER
If cam or valve contact surface of valve rocker is worn or dented, repair by removing the minimum necessary amount. If worn heavily, replace valve rocker.
VALVE LASH ADJUSTER






1. With adjuster set in vertical position, push adjuster pivot quick and hard by hand.
If pivot is depressed more than 0.5 mm (0.020 in), put adjuster in a container filled with light oil, and move plunger up and down until the depression is less than 0.5 mm (0.020 in).
2. If pivot is depressed more than 0.5 mm (0.020 in) even after repeating the above procedure, replace adjuster. The new adjuster is provided with a pin which must be removed before using.
ASSEMBLY
1. Press-fit oil seal into camshaft support by using INSTALLER (498037000), then attach 0-ring.
2. Install oil relief valve, relief valve spring, oil relief pipe, and oil relief plug to camshaft case.
Tightening torque: 23 - 26 N.m (2.3 - 2.7 kg-m, 17 - 20 ft-lb).
3. Install woodruff key to camshaft, then press-fit distributor drive gear by using CAMSHAFT HOLDER (498027000).
4. Insert camshaft into camshaft case, and install camshaft support.
Tightening torque: 5.9-6.9 N.m (0.60-0.70 kg-m, 4.3 - 5.1 ft-lb).
INSTALLATION






1. Insert valve lash adjusters into cylinder head. Be sure to insert each valve lash adjuster to its original position.
2. Apply grease to spherical surface and sliding surface of each valve rocker, then secure valve rockers to the respective valve adjusters and valves. Be sure to apply grease; otherwise, valve rocker will drop off.





3. Install 0-ring to camshaft case by setting camshaft so that camshaft straight pin is oriented as shown.






4. Apply fluid packing (Three-bond 1215, or equivalent) to groove of each camshaft case, then install to cylinder head. After installing, abundantly apply engine oil to sliding surfaces of cam and valve rocker.
Tightening torque: 17.2-20.1 N.m (1.75-2.05 kg-m, 12.7 - 14.8 ft-lb).
5. Attach gaskets to valve rocker covers, and install the covers to camshaft cases with rocker cover washers and bolts. Be extremely careful not to cause oil to leak from mating faces of valve rocker cover and camshaft case.
Tightening torque: 4.4-5.4 N.m (0.45-0.55 kg-m, 3.3 - 4.0 ft-lb).
6. Install PCV hoses.
7. Install EGR pipe, pipe clamps and EGR pipe cover. [TURBO MODEL]
. Install oil filler duct.
9. Install water pipe.
10. Install timing belt, belt cover and related parts. (Refer to Timing Belt and Belt Cover". Service and Repair





11. Install distributor, proceeding as follows:
(a) Bring # 1 cylinder piston to its top dead center on compression stroke. Set camshaft sprocket to the position shown in Figure.






(b) Align distributor housing match mark with pinion gear match mark to set # 1 cylinder at igniting position.
(c) Install distributor to camshaft case.
(d) Connect lead wires.
(e) Install plug cord and high-tension cord.
12. Install right and left belt covers.