Toyota Celica 1994-1998 Repair Guide

Camshaft, Bearings and Lifters

Print

REMOVAL & INSTALLATION



5S-FE Engine

See Figures 1 through 13

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to theLOCKposition and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.

  1. Label and disconnect the plug wires from the spark plugs. Make note of the proper firing order for installation.
  2.  
  3. Remove the timing belt, gears, and the covers.
  4.  
  5. Remove or disconnect any wire harnesses, clamps, cables, or components necessary in order to remove the cylinder head cover.
  6.  
  7. Remove the four nuts, grommets, head cover, and the gasket.
  8.  
  9. Set the No. 1 cylinder to TDC. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing belt cover. Check that the valve lifters on the No. 1 cylinder are loose and valve lifters on the No. 4 cylinder are tight. If not, rotate the crankshaft 360°.
  10.  

Since the thrust clearance on both the intake and exhaust camshafts is small, the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may damage the bearing surface, causing the camshaft to seize during engine operation.

  1. To remove the exhaust camshaft proceed as follows:
    1. Set the knock pin of the intake camshaft at 10-45°BTDC of camshaft angle on the cylinder head. This angle will help to lift the exhaust camshaft level and evenly by pushing the No. 2 and No. 4 cylinder camshaft lobes of the exhaust camshaft toward their valve lifters evenly.
    2.  
    3. Secure the exhaust camshaft sub-gear to the main gear using a service bolt. The manufacturer recommends a bolt 0.63-0.79 inch (16-20mm) long with a thread diameter of 6.0mm and a 1.0mm thread pitch. When removing the exhaust camshaft be sure that the torsional spring force of the sub-gear has been eliminated.
    4.  
    5. Remove the 2 bolts and the rear bearing cap.
    6.  
    7. Uniformly loosen and remove the bearing cap bolts on the No. 1, No. 2, and No. 4 bearing caps in several passes, in the sequence shown.
    8.  

  2.  

Do not remove bearing cap bolts to No. 3 bearing cap at this time.

  1. Remove the No. 1, 2, and 4 bearing caps.
  2.  
  3. Alternately loosen and remove the bearing cap bolts on the No. 3 bearing cap. As these bolts are loosened check to see that the camshaft is being lifted out straight and level.
  4.  

If the camshaft is not lifted out straight and level, tighten the No. 3 bearing cap bolts. Reverse the order of Steps 7f through 7a and reset the intake camshaft knock pin to 10-45°BTDC, then repeat Steps 7b through 7f. Do not attempt to pry the camshaft from its mounting.

  1. Remove the No. 3 bearing cap and exhaust camshaft from the engine.

    Click image to see an enlarged view

    Fig. Fig. 1: Set the knock pin of the intake camshaft at 10-45°BTDC-5S-FE engine



    Click image to see an enlarged view

    Fig. Fig. 2: Place a service bolt with the correct diameter, thread pitch and thread length through the cam sub and drive gears



    Click image to see an enlarged view

    Fig. Fig. 3: Remove the 2 bolts for the rear bearing cap first, then ... .



    Click image to see an enlarged view

    Fig. Fig. 4: ... uniformly remove the No. 1, No. 2 and No. 4 caps in several passes on the exhaust side-5S-FE engine

  2.  



To remove the intake camshaft, proceed as follows:
  1. Set the knock pin of the intake camshaft at 80-115°BTDC of the camshaft angle on the cylinder head. This angle will help to lift the intake camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the intake camshaft toward their valve lifters.
  2.  
  3. Remove the two front bearing cap bolts and extract the front bearing cap and oil seal. If the cap will not come apart easily, leave it in place without the bolts.
  4.  
  5. Uniformly loosen and remove the bearing cap bolts to No. 1, No. 3, and the No. 4 bearing caps in sequence in several passes. Do not remove bearing cap bolts to the No. 2 bearing cap at this time. Remove No. 1, No. 3, and No. 4 bearing caps.
  6.  
  7. Alternately loosen and remove bearing cap bolts to the No. 2 bearing cap. As these bolts are loosened and after breaking the adhesion on the front bearing cap, check to see that the camshaft is being lifted out straight and level.
  8.  

  1. Install the valve lifters into their original positions and install the shims. Make sure the lifter rotates smoothly by hand.
  2.  
  3. Before installing the intake camshaft, apply multi-purpose grease to the camshaft.
  4.  
  5. To install the intake camshaft, proceed as follows:
    1. Position the camshaft at 80-115°BTDC of camshaft angle on the cylinder head.
    2.  
    3. Apply sealant to the No. 1 bearing cap.
    4.  
    5. Coat the bearing cap bolts under the head and on the threads with clean engine oil.
    6.  
    7. Tighten the camshaft bearing caps evenly in sequence and in several passes to 14 ft. lbs. (19 Nm).
    8.  
    9. Apply MP grease to a new oil seal lip, and by using a suitable tool, tap a new oil seal into place.

      Click image to see an enlarged view

      Fig. Fig. 8: Always apply MP grease to the bearing caps before installing them



      Click image to see an enlarged view

      Fig. Fig. 9: Install the intake bearing caps in their proper locations-5S-FE exhaust



      Click image to see an enlarged view

      Fig. Fig. 10: Uniformly tighten the intake bearing cap bolts in several passes-5S-FE engine

    10.  

  6.  
  7. To install the exhaust camshaft, proceed as follows:
    1. Set the knock pin of the camshaft at 10-45°BTDC of camshaft angle on the cylinder head.
    2.  
    3. Apply multipurpose grease to the thrust portion of the camshaft.
    4.  
    5. Position the exhaust camshaft gear with the intake camshaft gear so that the timing marks are in alignment with one another. Be sure to use the proper alignment marks on the gears. Do not use the assembly reference marks.
    6.  
    7. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.
    8.  
    9. Instsall the bearing caps in their proper locations.
    10.  
    11. Coat the bearing cap bolts under the head and to the threads with clean engine oil.
    12.  
    13. Tighten the camshaft bearing caps evenly in sequence and in several passes to 14 ft. lbs. (19 Nm). Remove the service bolt from the assembly.

      Click image to see an enlarged view

      Fig. Fig. 11: Engage the exhaust camshaft gear to the intake gear by matching the timing marks-5S-FE exhaust



      Click image to see an enlarged view

      Fig. Fig. 12: Place the exhaust bearing caps in the proper locations-5S-FE exhaust



      Click image to see an enlarged view

      Fig. Fig. 13: Exhaust bearing cap tightening sequence-5S-FE exhaust

    14.  

  8.  
  9. Check and adjust valve clearance. Refer to General Information & Maintenance .
  10.  
  11. Install the cylinder head cover with the grommets and the four nuts.
  12.  
  13. Install the timing belt and related components.
  14.  
  15. Connect the electrical wiring, cables, brackets, and components attached to the cylinder head cover.
  16.  
  17. Install the spark plug wires and connect the negative battery cable. Start the engine, check for leaks, and road test the vehicle for proper operation.
  18.  

 

7A-FE Engine

See Figures 14, 15, 16, 17, 18, 19, 20, 21, 22 and 23

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Disconnect the spark plug wires from the spark plugs. Be sure to make note of the proper firing order for easier installation.
  4.  

  1. Remove the valve cover.
  2.  
  3. Remove the timing belt covers.
  4.  
  5. Remove the timing belt and idler pulley.
  6.  

  1. Set the exhaust camshaft so that the knock pin is slightly above the cylinder head. This angle allows the No. 1 and No. 3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.
  2.  

  1. Remove the two bolts and the front bearing cap of the intake camshaft.
  2.  



Click image to see an enlarged view

Fig. Fig. 14: Always remove the No. 1 bearing cap first on the intake side

  1. Secure the intake camshaft end gear to the sub-gear with a service bolt. The service bolt should match the following specifications:

    Thread diameter: 6.0mm
     
    Thread pitch: 1.0mm
     
    Bolt length: 16mm
     

  2.  



Click image to see an enlarged view

Fig. Fig. 15: Secure the intake camshaft with a service bolt at the end of the sub-gear

  1. Uniformly loosen each intake camshaft bearing cap bolt in several passes in the reverse order of the installation sequence.
  2.  


WARNING
The camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the thrust may crack or become damaged. In turn, this could cause the camshaft to bind or break. Before removing the intake camshaft, make sure the rotational force has been removed from the sub-gear; that is, the gear should be in a neutral or "unloaded" state.



Click image to see an enlarged view

Fig. Fig. 16: Lift the camshaft out straight and level

  1. Remove the four bearing caps and remove the intake camshaft.
  2.  

If the camshaft cannot be removed straight and level, install and tighten the No. 3 bearing cap. Alternately loosen the bolts on the bearing cap a little at a time while pulling upwards on the camshaft gear. DO NOT attempt to pry or force the cam loose with tools.

  1. With the intake camshaft removed, turn the exhaust camshaft approximately 105°, so that the guide pin in the end is just past the 5 o'clock position. This angle allows the No. 1 and the No. 3 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.
  2.  



Click image to see an enlarged view

Fig. Fig. 17: Set the knock pin on the exhaust camshaft slightly counterclockwise from the vertical axis of the cam

  1. Loosen the camshaft bearing cap bolts a little at a time and in the reverse order of the installation sequence.
  2.  
  3. Remove the 2 bolts, No. 1 bearing cap and oil seal.
  4.  



Click image to see an enlarged view

Fig. Fig. 18: Remove the No. 1 bearing cap off the exhaust side with the oil seal, if hard to remove, do not force it

If the No. 1 bearing cap is not removable by hand, do not try to remove it by force but leave it as it is without bolts.

  1. Remove the bearing caps and remove the exhaust camshaft. After removal, label each cap.
  2.  

If the camshaft cannot be removed straight and level, install and tighten the No. 3 bearing cap. Alternately loosen the bolts on the bearing cap a little at a time while pulling upwards on the camshaft gear. DO NOT attempt to pry or force the cam loose with tools.

Click image to see an enlarged view

Fig. Fig. 19: Remember, remove the camshaft straight and level

  1. Remove the valve lifter shims and hydraulic lifters. Identify each lifter and shim as it is removed so it can be reinstalled in the same position. If the lifters are to be reused, store them upside down in a sealed container.
  2.  

To install:
  1. Install the valve lifters into their original positions and install the shims. Check valve clearance and replace the shims as necessary.
  2.  
  3. When reinstalling, remember that the camshafts must be handled carefully and kept straight and level to avoid damage.
  4.  
  5. Apply multi-purpose grease to the portion of the camshaft.
  6.  
  7. Place the exhaust camshaft on the cylinder head so that the cam lobes press evenly on the lifters for cylinders Nos. 1 and 3. This will place the guide pin on the camshaft slightly counter clockwise from the vertical axis (about 5 o'clock).
  8.  



Click image to see an enlarged view

Fig. Fig. 20: Install the 4 bearing caps on the intake side in their proper locations-7A-FE engine

  1. Apply a light coat of clean engine oil to the camshaft bearing cap bolts. Install the five bearing caps in position according to the number cast into the cap. The arrow should point towards the pulley end (front) of the motor.
  2.  
  3. Tighten the bearing cap bolts uniformly and in several passes in the proper sequence to 9 ft. lbs. (13 Nm).
  4.  



Click image to see an enlarged view

Fig. Fig. 21: Install camshaft bearing tightening sequence-7A-FE engine

  1. Apply multi-purpose grease to a new exhaust camshaft oil seal.
  2.  
  3. Install the exhaust camshaft oil seal using a seal driver. Be very careful not to install the seal on a slant or allow it to tilt during installation.
  4.  
  5. Set the exhaust camshaft so that the guide pin is slightly above the cylinder head.
  6.  
  7. Apply multi-purpose grease to the portion of the intake camshaft.
  8.  
  9. Hold the intake camshaft next to the exhaust camshaft and engage the gears by matching the alignment marks on each gear.
  10.  

DO NOT use the TDC timing marks for the timing belt.

  1. Keeping the gears engaged, roll the intake camshaft down and into its bearing journals. This angle allows the No. 1 and the No. 3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.
  2.  
  3. Apply a light coat of clean engine oil to the camshaft bearing cap bolts and install the four bearing caps. Observe the numbers on each cap and make certain the arrows point to the pulley end (front) of the motor.
  4.  



Click image to see an enlarged view

Fig. Fig. 22: Position the exhaust 5 bearing caps in there correct locations-7A-FE engine

  1. Uniformly tighten each of the eight bearing cap bolts in several passes in the proper sequence. Tighten each bolt to 9 ft. lbs. (13 Nm).
  2.  



Click image to see an enlarged view

Fig. Fig. 23: Exhaust camshaft bearing tightening sequence-7A-FE engine

  1. Remove any retaining pins or bolts in the intake camshaft gears.
  2.  
  3. Apply a light coat of clean engine oil to the camshaft bearing cap bolts and install the No. 1 bearing cap for the intake camshaft. Tighten the bearing cap bolts to 9 ft. lbs. (13 Nm).
  4.  

If the No. 1 bearing cap does not fit properly, push the camshaft gear backwards by prying apart the cylinder head and camshaft gear with a suitable tool.

  1. Turn the exhaust camshaft clockwise, and set it with the guide pin facing upward. Check that the timing marks of the camshaft gears are aligned. The camshaft assembly installation marks should now be in the 12 o'clock position.
  2.  
  3. Secure the exhaust camshaft and install the timing belt pulley. Tighten the bolt to 43 ft. lbs. (59 Nm).
  4.  
  5. Check and adjust valve clearance.
  6.  
  7. Make sure that both the crankshaft and camshaft positions are set correctly, insuring that they are both set to TDC/compression for No. 1 cylinder.
  8.  
  9. Install the timing belt.
  10.  
  11. Install the timing belt covers and the valve cover.
  12.  
  13. Install the spark plug wires and connect the negative battery cable.
  14.  
  15. Start the engine, check for leaks, and check the ignition timing.
  16.  
  17. Road test the vehicle for proper operation.
  18.  

INSPECTION



Camshaft Runout

Camshaft runout should be checked when the camshaft has been removed from the engine. An accurate dial indicator is needed for this procedure; engine specialists and most machine shops have this equipment. If you have access to a dial indicator, or can take your camshaft to someone who does, measure the camshaft bearing journal runout. If the runout exceeds the limit replace the camshaft.

Camshaft Lobe Height

See Figure 24

Use a micrometer to check camshaft (lobe) height, making sure the anvil and the spindle of the micrometer are positioned directly on the heel and tip of the camshaft lobe as shown in the accompanying illustration.



Click image to see an enlarged view

Fig. Fig. 24: Using a micrometer to measure camshaft lobe height

Camshaft Journals

See Figure 25

Using a micrometer, measure the journal diameter.

5S-FE:


1.0614-1.0620 inch (26.959-26.975mm)
 

7A-FE:


Exhaust No. 1-0.9822-0.9829 inch (24.949-24.965mm)
 
Others-0.9035-0.9041 inch (22.949-22.965mm)
 



Click image to see an enlarged view

Fig. Fig. 25: Use a micrometer to measure the camshaft journals

If the diameters not as specified, check the oil clearance.

Camshaft Gear Spring

See Figure 26

Using a vernier caliper, measure the free distance between the spring ends.

5S-FE:


0.886-0.902 inch (22.5-22.9mm)
 

7A-FE:


0.669-0.693 inch (17.0-17.6mm)
 



Click image to see an enlarged view

Fig. Fig. 26: Measure the distance between each end of the gear spring

If the free distance is not within specifications, replace the gear spring.

Bearing Oil Clearance

See Figures 27, 28, 29 and 30

  1. Clean the bearing caps and camshaft journals.
  2.  
  3. Place the camshafts on the cylinder head.
  4.  

Measure the bearing oil clearance by placing a piece of Plastigage®on each bearing journal. Replace the bearing caps and tighten the bolts to the proper torque.

Do not turn the camshaft.



Click image to see an enlarged view

Fig. Fig. 27: Lay a strip of Plasitgage across each camshaft journal, then ... .



Click image to see an enlarged view

Fig. Fig. 28: ... install the bearing cap and tighten ...

  1. Remove the caps and measure each piece of Plastigage®at its widest point. If the clearance is greater than the values on the Engine Mechanical Specifications chart, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
  2.  
  3. Check the camshaft bearings for flaking and scoring. If the bearings show any signs of damage, replace the bearing caps and the cylinder head as a set.
  4.  



Click image to see an enlarged view

Fig. Fig. 29: ... next remove the caps, then ...



Click image to see an enlarged view

Fig. Fig. 30: ... measure the Plastigage®at its widest point

  1. Completely remove the Plastigage.
  2.  

Checking Camshaft End-Play

After the camshaft has been installed, end-play should be checked. The camshaft sprocket should not be installed on the cam. Use a dial gauge to check the end-play, by moving the camshaft forward and backward in the cylinder head. End-play specifications should be as noted in the Engine Mechanical Specifications chart.

Lifters and Bores

See Figures 31 and 32

Using a caliper gauge, measure the lifter bore diameter of the cylinder head.

5S-FE:


1.2205-1.2213 inch (31.000-31.018mm)
 

7A-FE:


1.2205-1.2215 inch (31.000-31.025mm)
 



Click image to see an enlarged view

Fig. Fig. 31: Using a caliper gauge, measure the lifter bore diameter of the cylinder head

Using a micrometer, measure the lifter diameter. Lifter diameter for both engines is 1.2191-1.2195 inch (30.966-30.976mm).



Click image to see an enlarged view

Fig. Fig. 32: A micrometer measures the lifter diameter

 
label.common.footer.alt.autozoneLogo