Protege 1999-2000

Camshaft, Bearings & Lifters

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Removal & Installation



1.6L (Zm) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Label the caps so they can be reinstalled in their original positions.



    Negative battery cable
     
    Spark plug wires
     
    Spark plugs

    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.6L (ZM) engines

     
    Cylinder head cover hoses, if equipped
     
    Cylinder head cover bolts
     
    Cylinder head cover
     
    Timing belt
     
    Camshaft by holding it with a wrench on the hexagon cast into the camshaft
     
    Sprocket bolts
     
    Sprockets
     



    Camshaft cap bolts by loosening in 2-3 steps in the sequence shown
     
    Camshaft caps
     

  4.  

To install:


CAUTION
Because there is little thrust clearance, the camshaft must be held in the horizontal position during installation. If not excessive force will be applied to the thrust area causing a burr on the receiving area of the cylinder head journal. Make sure to use the following procedure to avoid damage.

  1.  
  2. Install or connect the following:

    Lubricate the camshaft journals and lobes with clean engine oil
     
    Camshafts onto the head facing the cam noses at the no. 1 and 3 cylinders as illustrated. Make sure the camshaft sliding surface is free of sealant.

    Click image to see an enlarged view

    Fig. Install the camshafts onto the head facing the cam noses at the no. 1 and 3 cylinders as shown-1.6L (ZM)



    Click image to see an enlarged view

    Fig. Apply silicone sealant to the cylinder head in the positions shown-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.6L (ZM) engines

     

  3.  
  4. Apply a 0.04 inch (1mm) bead of silicone sealant to the areas illustrated in the illustration. Do not allow any sealant on the camshaft journals.
  5.  
  6. Install or connect the following:

    Camshaft caps in their original positions
     
    Cap bolts and hand tighten bolts 5, 7, 2 and 4
     
    Cap bolts a few turns in the sequence illustrated
     

  7.  
  8. Make sure the camshaft settles horizontally when the bearing cap bolts at the number 3 journals are tightened. Torque the bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.

    New camshaft seal by lubricating it with engine oil. Tap the seal into position, using a seal installer, until it is recessed into the cylinder head 0.01 inch (0.4mm) on the 1.6L (ZM) engines and 0.012-0.027 inch (0.3-0.7mm) on 1.8L (FP) engines.
     

  9.  
  10. Turn the camshafts until the dowel pins face straight up.
  11.  
  12. Install or connect the following:

    Camshaft sprockets. Torque the bolts to 44 ft. lbs. (60 Nm) by holding the camshaft with the wrench on the cast hexagon.
     
    Remaining components
     

  13.  

 
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