ION, L-Series, S-Series 1999-2005

Camshaft, Bearings & Lifters

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Inspection



  1. Clean the camshaft in solvent and allow it to dry.
  2.  
  3. 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.
  4.  
  5. Position 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 run-out limit at the center journal is 0.004 in. (0.1mm) for DOHC engines or 0.0028 in. (0.07mm) for SOHC engines. Replace the camshaft if run-out is excessive.
  6.  
  7. Using a micrometer, measure the camshaft lobes across their maximum and minimum lobe height dimensions. Subtract the lobe width from the lobe height to arrive at lobe rise. Replace a SOHC camshaft if any lobes have a rise of less than 0.252 in. (6.4mm). Replace a DOHC camshaft if any intake rise is less than 0.351 in. (8.91mm), or any exhaust rise is less than 0.339 in. (8.61mm).
  8.  
  9. Using a micrometer, measure the diameter of the journals and replace any camshaft containing a journal that is less than the minimum. For SOHC engines, journal diameter should be greater than 1.747 in. (44.375mm). DOHC engines should have a minimum camshaft journal diameter of 1.139 in. (28.925mm).
  10.  
  11. Measure the diameter of the camshaft bearings. For the DOHC engine, temporarily install the bearing caps to the cylinder head in order to take the measurement. Bore diameter must be less than 1.753 in. (44.513mm) for SOHC engines or 1.144 in. (29.05mm) for DOHC engines, or the cylinder head must be replaced.
  12.  
  13. Subtract the journal diameter measurements from their respective bore diameter measurements to calculate oil clearance. Replace the camshaft and/or cylinder head if clearance is more than 0.0054 in. (0.138mm) for SOHC engines or 0.005 in. (0.125mm) for DOHC engines.
  14.  
  15. Position a precision straightedge across the bottom of the cylinder head camshaft contact surfaces. Use a feeler gauge to inspect for warpage; replace a cylinder head with warpage of more than 0.0025 in. (0.064mm) for SOHC engines or 0.003 in. (0.075mm) for DOHC engines.

    Click image to see an enlarged view

    Fig. Use a dial indicator to measure camshaft run-out at the center journal



    Click image to see an enlarged view

    Fig. Subtract the lobe width from the height to determine lobe rise



    Click image to see an enlarged view

    Fig. Measure camshaft journal diameter using a micrometer



    Click image to see an enlarged view

    Fig. Measuring camshaft contact surface warpage-DOHC engine shown

  16.  

  1. Clean the camshaft in solvent and allow it to dry.
  2.  
  3. 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.
  4.  
  5. Position 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 run-out limit at the center journal is 0.004 in. (0.1mm) for DOHC engines or 0.0028 in. (0.07mm) for SOHC engines. Replace the camshaft if run-out is excessive.
  6.  
  7. Using a micrometer, measure the camshaft lobes across their maximum and minimum lobe height dimensions. Subtract the lobe width from the lobe height to arrive at lobe rise. Replace a SOHC camshaft if any lobes have a rise of less than 0.252 in. (6.4mm). Replace a DOHC camshaft if any intake rise is less than 0.351 in. (8.91mm), or any exhaust rise is less than 0.339 in. (8.61mm).
  8.  
  9. Using a micrometer, measure the diameter of the journals and replace any camshaft containing a journal that is less than the minimum. For SOHC engines, journal diameter should be greater than 1.747 in. (44.375mm). DOHC engines should have a minimum camshaft journal diameter of 1.139 in. (28.925mm).
  10.  
  11. Measure the diameter of the camshaft bearings. For the DOHC engine, temporarily install the bearing caps to the cylinder head in order to take the measurement. Bore diameter must be less than 1.753 in. (44.513mm) for SOHC engines or 1.144 in. (29.05mm) for DOHC engines, or the cylinder head must be replaced.
  12.  
  13. Subtract the journal diameter measurements from their respective bore diameter measurements to calculate oil clearance. Replace the camshaft and/or cylinder head if clearance is more than 0.0054 in. (0.138mm) for SOHC engines or 0.005 in. (0.125mm) for DOHC engines.
  14.  
  15. Position a precision straightedge across the bottom of the cylinder head camshaft contact surfaces. Use a feeler gauge to inspect for warpage; replace a cylinder head with warpage of more than 0.0025 in. (0.064mm) for SOHC engines or 0.003 in. (0.075mm) for DOHC engines.

    Click image to see an enlarged view

    Fig. Use a dial indicator to measure camshaft run-out at the center journal



    Click image to see an enlarged view

    Fig. Subtract the lobe width from the height to determine lobe rise



    Click image to see an enlarged view

    Fig. Measure camshaft journal diameter using a micrometer



    Click image to see an enlarged view

    Fig. Measuring camshaft contact surface warpage-DOHC engine shown

  16.  

Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the ignition coils.
  6.  
  7. Remove the ground strap and stud.
  8.  
  9. Disconnect the Positive Crankcase Ventilation (PCV) hose from the cam cover.
  10.  
  11. Disconnect the fuel feed pipe from the fuel rail.
  12.  
  13. Remove the camshaft cover bolts.
  14.  
  15. Remove the camshaft cover.
  16.  
  17. Remove the upper timing chain guide.
  18.  
  19. Install camshaft sprocket holding tool J 43655.
  20.  
  21. Remove both the intake and exhaust camshaft sprocket bolts and discard.
  22.  
  23. Slide the camshaft sprockets forward.
  24.  
  25. Mark the caps to ensure they are installed in the original position.
    NOTE
    Remove each bolt on each cap one turn at a time until there is no spring tension on the camshaft.

  26.  
  27. Remove the caps.
  28.  
  29. Remove the camshaft.
  30.  
  31. Remove the camshaft roller followers.
  32.  
  33. Remove the hydraulic lash adjusters.
  34.  

To install:

  1. Lubricate the valve tips.
  2.  
  3. Install the hydraulic lash adjusters.
  4.  
  5. Install the camshaft roller followers.
  6.  
  7. Ensure that the alignment notches are aligned with the camshaft sprocket.
  8.  
  9. Install the intake camshaft.
  10.  
  11. Install the camshaft caps.
  12.  
  13. Tighten the caps in increments of 3 turns until they are seated, then tighten to 89 inch lbs. (10 Nm).
  14.  
  15. Apply 0.138 inch (3.55mm) of Permatex Anaerobic Gasket maker® 51813 to the rear camshaft bearing cap. Install the cap and tighten the bolts to 18 ft. lbs. (25 Nm).
  16.  
  17. Install camshaft sprockets onto the camshafts.
  18.  
  19. Hand tighten NEW camshaft sprocket bolts.
  20.  
  21. Remove camshaft sprocket holding tool J43655
  22.  
  23. Tighten the camshaft sprocket bolts and tighten to 63 ft. lbs. (85 Nm) plus and additional 30 degrees
  24.  
  25. Install the upper timing chain guide and tighten to 89 inch lbs. (10 Nm).
  26.  
  27. Install the camshaft cover and bolts and tighten to 89 inch lbs. (10 Nm).
  28.  
  29. Install the ground strap to the camshaft cover and tighten to 89 inch lbs. (10 Nm).
  30.  
  31. Install the ignition coils .
  32.  
  33. Connect the fuel feed pipe to the fuel rail.
  34.  
  35. Install the fuel pipe bracket and tighten to 89 inch lbs. (10 Nm).
  36.  
  37. Connect the PCV hose to the cam cover
  38.  
  39. Connect the negative battery cable.
  40.  

2.2L & 2.4L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accelerator cable from the throttle body and bracket
     
    Accelerator bracket bolts and the bracket
     
    Positive Crankcase Ventilation (PCV) hose
     
    Fuel line bracket
     
    Ignition Coil Module (ICM) connector
     
    ICM screws and the ICM
     
    Ignition coil housing bolts and the housing
     
    Ground strap stud from the camshaft cover
     
    Ground strap
     
    Camshaft cover bolts
     
    Camshaft cover
     
    Upper timing chain guide
     

  4.  
  5. Install camshaft sprocket holding tool J43655 as illustrated.

    Click image to see an enlarged view

    Fig. Remove the upper timing chain guide-ION



    Click image to see an enlarged view

    Fig. Install camshaft sprocket holding tool J43655-ION



    Intake and exhaust camshaft sprocket bolts and discard the bolts
     

  6.  
  7. Slide the sprockets forward and mark the camshaft bearing caps to ensure they are installed in their correct positions.
  8.  
  9. Remove each bearing cap bolt one turn at a time until there is no tension.
  10.  
  11. Remove the bearing cap and the camshaft

    Roller followers
     
    Lash adjusters
     

  12.  

To install:

  1. Lubricate the valve tips.
  2.  
  3. Install or connect the following:

    Lash adjusters
     
    Roller followers
     

  4.  
  5. Make sure the alignment notches are aligned with the camshaft sprocket as illustrated.

    Click image to see an enlarged view

    Fig. Make sure the alignment notches are aligned with the camshaft sprocket-ION



    Click image to see an enlarged view

    Fig. Apply 0.197 inch (5mm) on 2.2L engines or 0.138 inch (3.55mm) of anaerobic Gasket maker to the rear camshaft bearing cap-ION



    Camshaft
     
    Bearing caps except the rear camshaft cap
     

  6.  
  7. Tighten the caps in increments of 3 turns until they are seated, then tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Apply 0.197 inch (5mm) of Permatex Anaerobic Gasket maker® 51813 to the rear camshaft bearing cap. Install the cap and tighten the bolts to 18 ft. lbs. (25 Nm).

    Camshaft sprockets and hand tighten the bolts
     

  10.  
  11. Remove camshaft sprocket holding tool J43655

    Camshaft sprocket bolts to 63 ft. lbs. (85 Nm) plus and additional 30 degrees
     

  12.  
  13. Install or connect the following:

    Upper timing chain guide and tighten to 89 inch lbs. (10 Nm)
     
    Camshaft cover
     
    Camshaft cover bolts and tighten to 89 inch lbs. (10 Nm)
     
    Ground strap
     
    Ground strap stud to the camshaft cover and tighten to 89 inch lbs. (10 Nm)
     
    Ignition coil housing and tighten the bolts to 89 inch lbs. (10 Nm)
     
    ICM and tighten the screws to 13 inch lbs. (1.5 Nm)
     
    ICM connector
     
    Fuel line bracket
     
    PCV hose
     
    Accelerator bracket and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Accelerator cable to the throttle body and bracket
     
    Air cleaner assembly
     
    Negative battery cable
     

  14.  

2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Accelerator cable from the throttle body and bracket
     
    Accelerator bracket bolts and the bracket
     
    Positive Crankcase Ventilation (PCV) hose
     
    Fuel line bracket
     
    Ignition Coil Module (ICM) connector
     
    ICM screws and the ICM
     
    Ignition coil housing bolts and the housing
     
    Ground strap stud from the camshaft cover
     
    Ground strap
     
    Camshaft cover bolts
     
    Camshaft cover
     
    Upper timing chain guide
     

  4.  
  5. Install camshaft sprocket holding tool J43655 as illustrated.

    Click image to see an enlarged view

    Fig. Remove the upper timing chain guide-ION



    Click image to see an enlarged view

    Fig. Install camshaft sprocket holding tool J43655-ION



    Intake and exhaust camshaft sprocket bolts and discard the bolts
     

  6.  
  7. Slide the sprockets forward and mark the camshaft bearing caps to ensure they are installed in their correct positions.
  8.  
  9. Remove each bearing cap bolt one turn at a time until there is no tension.
  10.  
  11. Remove the bearing cap and the camshaft

    Roller followers
     
    Lash adjusters
     

  12.  

To install:

  1. Lubricate the valve tips.
  2.  
  3. Install or connect the following:

    Lash adjusters
     
    Roller followers
     

  4.  
  5. Make sure the alignment notches are aligned with the camshaft sprocket as illustrated.

    Click image to see an enlarged view

    Fig. Make sure the alignment notches are aligned with the camshaft sprocket-ION



    Click image to see an enlarged view

    Fig. Apply 0.197 inch (5mm) on 2.2L engines or 0.138 inch (3.55mm) of anaerobic Gasket maker to the rear camshaft bearing cap-ION



    Camshaft
     
    Bearing caps except the rear camshaft cap
     

  6.  
  7. Tighten the caps in increments of 3 turns until they are seated, then tighten to 89 inch lbs. (10 Nm).
  8.  
  9. Apply 0.197 inch (5mm) of Permatex Anaerobic Gasket maker®51813 to the rear camshaft bearing cap. Install the cap and tighten the bolts to 18 ft. lbs. (25 Nm).

    Camshaft sprockets and hand tighten the bolts
     

  10.  
  11. Remove camshaft sprocket holding tool J43655

    Camshaft sprocket bolts to 63 ft. lbs. (85 Nm) plus and additional 30 degrees
     

  12.  
  13. Install or connect the following:

    Upper timing chain guide and tighten to 89 inch lbs. (10 Nm)
     
    Camshaft cover
     
    Camshaft cover bolts and tighten to 89 inch lbs. (10 Nm)
     
    Ground strap
     
    Ground strap stud to the camshaft cover and tighten to 89 inch lbs. (10 Nm)
     
    Ignition coil housing and tighten the bolts to 89 inch lbs. (10 Nm)
     
    ICM and tighten the screws to 13 inch lbs. (1.5 Nm)
     
    ICM connector
     
    Fuel line bracket
     
    PCV hose
     
    Accelerator bracket and tighten the bolts to 89 inch lbs. (10 Nm)
     
    Accelerator cable to the throttle body and bracket
     
    Air cleaner assembly
     
    Negative battery cable
     

  14.  

 
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