REMOVAL & INSTALLATION
- Disconnect the negative battery cable. Drain the cooling system to a level below the thermostat housing.
- Remove the timing belt covers, the timing belt and the camshaft sprocket.
- Disconnect the upper radiator hose and the electrical connectors from the thermostat housing.
- Mark the position of the distributor housing and the rotor and remove the distributor.
- Remove the rocker arm cover and the front and rear housings. If necessary, pry out the camshaft seal from the front housing.
- Remove the rocker arm/shaft assemblies.
- Remove the camshaft bearing caps and the camshaft.
- Clean all gasket mating surfaces.
- Apply a liberal amount of clean engine oil to the camshaft journals and bearings. Install the camshaft on the cylinder head with the dowel pin facing straight up.
- Apply silicone sealer to the cylinder head area shown in Fig.1. Do not let sealer come in contact with the camshaft bearings or journals.
- Install the camshaft bearing caps with the arrows facing the front of the engine. Install the rocker arm/shaft assemblies, making sure the notches on the end of the shafts are in the correct position. Tighten the bolts, in the sequence shown in Fig. 79B, to 13-20 ft. lbs. (18-26 Nm), in 2 equal steps.
- Install a new gasket and the rear housing. Tighten the bolts to 14-19 ft. lbs. (19-25 Nm).
- If the camshaft seal was removed, lubricate the lip of a new seal and install in the front housing, using a seal installation tool. Install a new gasket and the front housing. Tighten the bolts to 14-19 ft. lbs. (19-25 Nm).
- Install the rocker arm cover, tightening the retaining bolts to 52-69 inch lbs. (6-8 Nm).
- Install the distributor, aligning the marks that were made during the removal procedure.
- Connect the electrical connectors and the upper radiator hose.
- Install the camshaft sprocket, the timing belt and the timing belt covers.
- Fill the cooling system, connect the negative battery cable and start the engine. Check the ignition timing and check for leaks.
- Disconnect the negative battery cable. Remove the engine assembly from the vehicle and place it on a suitable workstand.
- Remove the timing covers, rocker arm covers and the intake manifold.
- Remove the hydraulic lifters using a magnet and keep them in order, so they may be reinstalled in their original positions. If the lifters are stuck in the bores, use a hydraulic lifter puller or equivalent, to remove them.
- Remove the timing chain and sprockets.
- Check the camshaft endplay as follows:
- Mount a dial indicator on the front of the cylinder block and rest the indicator foot on the end of the camshaft.
- Move the camshaft back and forth in the cylinder block and observe the dial indicator. If necessary, use a prybar to move the camshaft, but be careful not to damage the camshaft lobes or journals.
- If the endplay is excessive, replace the thrust plate.
- Remove the camshaft thrust plate. Remove the camshaft by pulling it toward the front of the engine.
- Clean and inspect all parts prior to installation.
- Lubricate the camshaft lobes and the journals with engine assembly lube. Carefully slide the camshaft through the bearings in the cylinder block.
- Install the thrust plate and tighten the bolts to 6-8 ft. lbs. (8-12 Nm).
- Install the timing chain and sprockets. Check the camshaft sprocket bolt for blockage of the drilled oil passages.
- Install the timing cover and the crankshaft damper.
- Lubricate the lifters and lifter bores with heavy engine oil and install the lifters into their original bores.
- Install the pushrods, rocker arms, rocker covers and intake manifold.
- Install the engine assembly and connect the negative battery cable.
- Fill the cooling system and the crankcase. Run the engine and check for leaks.
- Clean the camshaft in solvent and allow to dry.
- Inspect the camshaft for obvious signs of wear: scores, nicks or pits on the journals or lobes. Light scuffs or nicks can be removed with an oil stone.
- Using a micrometer, measure the diameter of the journals and compare to specifications. Replace the camshaft if any journals are not within specification.
- Measure the camshaft lobes across their maximum lobe height dimensions, using a micrometer. Compare your measurements with the lobe height specifications. Replace the camshaft if any lobe heights are not within specification.
- On the 2.2L engine, mount the camshaft in V-blocks with the front and rear journals riding on the blocks. Check if the camshaft is bent using a dial indicator on the center bearing journal. The limit at the center journal is 0.0012 in. (0.03mm). Replace the camshaft if runout is excessive.
- On the 2.2L engine, check the camshaft endplay with the camshaft laying in the cylinder on the lower bearing journals. Mount a dial indicator to the front of the cylinder head with the indicator foot resting on the end of the camshaft. Move the camshaft back and forth and observe the indicator. Compare the reading with the specification. If endplay is excessive, replace the camshaft or the cylinder head.