Camshaft

REMOVAL AND INSTALLATION

1993 Protege 1.8L (BPD) Engine

1. Disconnect the negative battery cable. Drain the cooling system.
2. Label and disconnect the spark plug wires and remove the spark plugs.
3. Disconnect the hoses from the cylinder head cover, if equipped.
4. Remove the cylinder head cover bolts and remove the cylinder head cover.
5. Remove the timing belt. Remove the distributor.
6. Hold the camshaft with a wrench on the hexagon cast into the camshaft. Remove the sprocket bolts and remove the sprockets.
7. Label the caps so they can be reinstalled in their original positions. Loosen the camshaft cap bolts in 2-3 steps in the reverse of the torque sequence, then remove the camshaft caps.
8. Remove the camshafts. Remove the camshaft oil seals from the camshafts.

   To install:

9. Lubricate the camshaft journals and lobes with clean engine oil. Install the camshafts in the cylinder head.
10. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
11. Install the camshaft caps in their original positions. Loosely install the cap bolts.
12. Tighten the camshaft cap bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.
13. Apply clean engine oil to the lip of a new camshaft seal. Push the seal slightly in by hand. Tap the seal into position, using a seal installer, until it is flush with the edge of the camshaft cap.
14. Turn the camshafts until the dowel pins face straight up. Install the camshaft sprockets and the sprocket bolts.
15. Hold the camshaft with the wrench on the cast hexagon and tighten the sprocket bolts to 44 ft. lbs. (60 Nm).
16. Install the remaining components in the reverse order of removal.

1995-97 Millenia 2.3L (KJS) Engine

1. Relieve the fuel system pressure. Disconnect the negative battery cable.
2. Remove the timing belt covers and timing belt.
3. Remove the spacer and O-ring from the front of the camshaft.
4. Remove the ignition coils.
5. Remove the intake manifold.
6. Remove the bolts, in 5-6 steps, using the reverse of the tightening sequence. Remove the cylinder head cover.
7. Remove the camshaft sprockets.
8. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the adjustment shims.
9. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right hand (rear) caps are marked with numbers and the left hand (front) caps are marked with letters.
10. Loosen the front camshaft cap bolts in the reverse of the torque sequence, in 5-6 steps. Remove the front camshaft caps.
11. Remove the remaining camshaft cap bolts in the proper sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
12. Remove the camshafts and oil seals.
13. If necessary, remove the lifters and adjustment shims. Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

    To install:

14. Apply clean engine oil to the lifters, then install them in their original positions. Verify that they move smoothly in their bore.
15. Install new oil seals on the camshafts. Apply clean engine oil to the camshaft lobes, journals and supports.
16. Install the camshafts so the gear marks align.
17. Remove all oil and dirt from the mating surfaces between the front camshaft cap and the cylinder head.
18. Install the thrust caps. Tighten the thrust cap bolts, in 5-6 steps, until the caps are fully seated on the cylinder head.
19. Apply silicone sealant, at a thickness of 0.06-0.09 inch (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity.
20. Install the remaining camshaft caps in their original positions. Tighten the caps, in sequence, in five equal steps, with the final step being 100-125 inch lbs. (11-14 Nm).
21. Apply clean engine oil to the lip of the new camshaft oil seal. Push the seal in lightly by hand. Tap the seal in evenly with a seal installer (49 F401 337A or equivalent) with a final protrusion of 0-0.02 inch (0-0.5mm). Tap in a new blind cap.
22. Install the camshaft sprockets. Tighten the mounting bolts to 91-103 ft. lbs. (123-140 Nm).
23. Measure and adjust valve clearances.
24. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
25. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps. Install a new gasket on the cylinder head.
26. Install the cylinder head cover. Tighten the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm).
27. Using a new O-ring, install the distributor.
28. Install the ignition coils.
29. Install the intake manifold.
30. Install the spacer, using a new O-ring. Tighten the mounting bolt to 14-18 ft. lbs. (19-25 Nm).
31. Install the timing belt and timing belt cover.
32. Connect the negative battery cable. Run the engine and check for leaks.

1995-97 Millenia 2.5L (KLD) Engine

1. Relieve the fuel system pressure. Disconnect the negative battery cable.
2. Remove the timing belt covers and timing belt.
3. Remove the air cleaner housing assembly.
4. Label and disconnect the spark plug wires from the spark plugs.
5. Remove the distributor.
6. Remove the intake manifold.
7. Remove the bolts, in 5-6 steps, using the reverse of the tightening sequence. Remove the cylinder head cover.
8. Remove the camshaft sprockets.
9. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the hydraulic lifters.
10. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right hand (rear) caps are marked with numbers and the left hand (front) caps are marked with letters.
11. Loosen the front camshaft cap bolts in sequence, in 5-6 steps. Remove the front camshaft caps.
12. Remove the remaining camshaft cap bolts in the proper sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
13. Remove the camshafts and oil seals.
14. If necessary, remove the hydraulic lifters. Identify and mark each lifter 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 an oil-filled sealed container.

    To install:

15. If removed, inspect each lifter by holding it in your hand and pressing the bottom up against the top of the lifter. If there is movement, replace the lifter.
16. Apply clean engine oil to the lifters, then install them in their original positions. Verify that they move smoothly in their respective bores.
17. Install new oil seals on the camshafts. Apply clean engine oil to the camshaft lobes, journals and supports.
18. Install the camshafts so the gear marks align.
19. Remove all oil and dirt from the mating surfaces between the front camshaft cap and the cylinder head.
20. Install the thrust caps. Tighten the thrust cap bolts, in 5-6 steps, until the caps are fully seated on the cylinder head.
21. Apply silicone sealant, at a thickness of 0.06-0.09 inch (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity and to the left cylinder head on the rear exhaust camshaft cap mating surface.
22. Install the remaining camshaft caps in their original positions. Tighten the caps, in sequence, in five equal steps, with the final step being 100-125 inch lbs. (11-14 Nm).
23. Apply clean engine oil to the lip of the new camshaft oil seal. Push the seal in lightly by hand. Tap the seal in evenly with a seal installer (49 F401 337A or equivalent) with a final protrusion of 0-0.02 inch (0-0.5mm).
24. Install the camshaft sprockets. Tighten the mounting bolts to 91-103 ft. lbs. (123-140 Nm).
25. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
26. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps. Install a new gasket on the cylinder head.
27. Install the cylinder head cover. Tighten the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm).
28. Install the intake manifold.
29. Using a new O-ring, install the distributor.
30. Install the spark plug wires.
31. Install the air cleaner housing assembly.
32. Install the timing belt and timing belt cover.
33. Connect the negative battery cable. Run the engine and check for leaks.

1993-95 929 3.0L (JE-ZE) Engines

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable, and drain the cooling system.
3. Remove the fresh air duct and air intake pipe.
4. Remove the cooling fan and shroud.
5. Disconnect the spark plug wires and remove the spark plugs. Remove the idler pulleys and the accessory drive belts.
6. Remove the coolant bypass hose and the upper radiator hose. Disconnect the electrical connector and remove the distributor.
7. Hold the crankshaft pulley with a suitable tool and remove the bolt. Remove the crankshaft pulley. Be careful not to damage the sensor rotor.
8. Remove the timing belt covers. Rotate the crankshaft until the camshaft and crankshaft sprocket timing marks are aligned.
9. Remove the upper idler pulley and the tensioner and pulley. Mark the direction of rotation on the timing belt and remove the timing belt.
10. Disconnect the accelerator cable. Disconnect and plug the fuel lines. Label and disconnect the necessary electrical connectors and vacuum hoses.
11. Loosen and remove the lower intake manifold bolts in 2-3 steps. Remove the lower intake manifold.
12. Remove the cylinder head covers.
13. Hold the camshaft with a wrench on the hexagon cast into the camshaft and remove the camshaft sprocket bolt. Remove the camshaft sprockets.
14. Remove bolts A from the front camshaft cap on the left cylinder head. Loosen the remaining camshaft cap bolts in 2-3 steps in the reverse of the torque sequence. Mark the position of the caps so they can be reinstalled in their original positions.
15. Remove the camshaft caps and remove the camshafts. Remove the camshaft oil seals. Label the camshafts so they can be reinstalled in their proper locations.
16. Lift out and label the rocker arms, if necessary.

    To install:

17. If removed, position the rocker arms.
18. Lubricate the camshaft lobes and journals with clean engine oil and install the camshafts on the cylinder heads. Apply clean engine oil to the lips of the new camshaft seals, if replaced, and install them on the camshafts.
19. Apply a small amount of silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow sealant to get on the camshaft journal, oil seal face or camshaft thrust face.
20. Install the camshaft caps in their original locations. Gradually tighten the cap bolts, in sequence, to 24 ft. lbs. (32 Nm). Tighten the front cap bolts, A, on the left cylinder head to 95 inch lbs. (11 Nm).
21. Hold the camshafts using a wrench on the hexagon cast into the camshaft. Install the camshaft sprockets with the retaining bolts. Tighten the sprocket bolts on the right cylinder head to 59 ft. lbs. (80 Nm) and the sprocket bolts on the left cylinder head to 19 ft. lbs. (25 Nm).
22. Apply sealant to the cylinder head in the areas adjacent to the front camshaft caps. Install the cylinder head covers and tighten the nuts to 39 inch lbs. (4 Nm).
23. Install the lower intake manifold using new gaskets. Tighten the mounting nuts in 2-3 steps, in the proper sequence, to 19 ft. lbs. (25 Nm). Connect the fuel lines.
24. Install the upper intake manifold to the lower intake manifold, using a new gasket. Tighten the bolts to 19 ft. lbs. (25 Nm).
25. Connect the electrical connectors and vacuum hoses. Connect the accelerator cable.
26. Position the timing belt tensioner on a suitable press. Place a flat washer at the bottom of the tensioner body to prevent damage to the body plug. Slowly press in the tensioner rod, but do not exceed 2200 lbs. Insert a pin in the tensioner body to hold the rod in place, then install the tensioner and tighten the mounting bolts to 19 ft. lbs. (25 Nm).
27. Make sure the crankshaft and camshaft sprocket timing marks are properly aligned. Install the timing belt over the sprockets and pulleys in the following order: crankshaft sprocket, lower idler pulley, left cylinder head exhaust cam sprocket, left cylinder head intake cam sprocket, tensioner pulley, right cylinder head exhaust cam sprocket and right cylinder head intake cam sprocket.
28. Push the belt down and install the upper idler pulley. Tighten the upper idler pulley bolt to 38 ft. lbs. (52 Nm). Make sure the camshaft and crankshaft sprocket timing marks are still aligned after installing the upper idler pulley.
29. Turn the crankshaft 2 revolutions in the normal direction of rotation and realign the timing marks. Make sure all timing marks are correctly aligned.
30. Remove the pin from the automatic tensioner and again rotate the crankshaft 2 turns. Confirm that the timing marks are aligned.
31. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm).
32. Install the crankshaft pulley. Hold the pulley with a suitable tool and tighten the pulley bolt to 123 ft. lbs. (167 Nm). Be careful not to damage the sensor rotor.
33. Install the spark plugs and the distributor assembly. Connect the spark plug wires and the distributor electrical connector.
34. Install the upper radiator hose and water bypass hose. Install the idler pulleys and accessory drive belts. Adjust the belt tension.
35. Install the shroud and cooling fan. Install the air intake pipe and fresh air duct.
36. Connect the negative battery cable. Fill and bleed the cooling system.
37. Start the engine and bring to normal operating temperature. Check for leaks. Check the ignition timing and idle speed.

1993-94 323 1.6L (B6E) and 1994 Protege 1.8L (BPD) Engines

NOTE: The camshaft is removed through the front of the cylinder head.

1. Remove the cylinder head from the vehicle and position in a suitable holding fixture.

   NOTE: Do not lay the cylinder head flat on the head gasket surface as the valves may be damaged.

2. On 1.6L and 1.8L engines, hold the camshaft with a wrench on the hexagon cast into the front of the camshaft.
3. Remove the sprocket bolt and the sprocket.
4. Loosen the rocker arm shaft bolts in 2-3 steps, in the reverse of the torque sequence. Remove the rocker arm and shaft assemblies.
5. Pry out the camshaft seal using a small prybar, being careful not to damage the camshaft or seal bore.
6. Remove the thrust plate at the rear of the cylinder head.
7. Carefully slide the camshaft from the cylinder head, being careful not to damage the cylinder head bearing surfaces.

   To install:

8. Lubricate the camshaft lobes and journals and the cylinder head bearing surfaces with clean engine oil.
9. Carefully slide the camshaft into the cylinder head, being careful not to damage the bearing surfaces.
10. Install the camshaft thrust plate. On the 1.6L 8-valve engine, tighten the thrust retaining bolt to 95 in. lbs. (11 Nm). On the 1.6L and 1.8L 16-valve engines, the thrust plate is held in place by the rocker arm and shaft assembly.
11. Lubricate the lip of a new camshaft seal with clean engine oil and install in the cylinder head, using a seal installer.
12. Lubricate the rocker arms and valve stem tips with clean engine oil. Install the rocker arm and shaft assemblies and tighten the bolts, in 2-3 steps, in the proper sequence. The final torque should be 21 ft. lbs. (28 Nm) on the 1.6L and 1.8L engines.
13. Install the camshaft sprocket and retaining bolt. Hold the camshaft with the wrench on the hexagon and tighten the bolt to 45 ft. lbs. (61 Nm).
14. Install the cylinder head and the remaining components in the reverse order of removal.

1993-94 Protege 1.8L (BPE) Engines

1. Disconnect the negative battery cable. Drain the cooling system.
2. Label and disconnect the spark plug wires and remove the spark plugs.
3. Disconnect the hoses from the cylinder head cover, if equipped.
4. Remove the cylinder head cover bolts and remove the cylinder head cover.
5. Remove the timing belt. Remove the distributor.
6. Hold the camshaft with a wrench on the hexagon cast into the camshaft. Remove the sprocket bolts and remove the sprockets.
7. Label the caps so they can be reinstalled in their original positions. Loosen the camshaft cap bolts in 2-3 steps in the reverse of the torque sequence, then remove the camshaft caps.
8. Remove the camshafts. Remove the camshaft oil seals from the camshafts.

   To install:

9. Lubricate the camshaft journals and lobes with clean engine oil. Install the camshafts in the cylinder head.
10. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
11. Install the camshaft caps in their original positions. Loosely install the cap bolts.
12. Tighten the camshaft cap bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.
13. Apply clean engine oil to the lip of a new camshaft seal. Push the seal slightly in by hand. Tap the seal into position, using a seal installer, until it is flush with the edge of the camshaft cap.
14. Turn the camshafts until the dowel pins face straight up. Install the camshaft sprockets and the sprocket bolts.
15. Hold the camshaft with the wrench on the cast hexagon and tighten the sprocket bolts to 44 ft. lbs. (60 Nm).
16. Install the remaining components in the reverse order of removal.

1995-97 Protege 1.5L (Z5D) and 1.8L (BPE, BPD) Engines

1. Disconnect the negative battery cable.
2. Remove the power steering hose brackets from the cylinder head cover.
3. Label and disconnect the spark plug wires and spark plug wire clips.
4. Disconnect the breather tube and PCV valve from the cylinder head cover. Loosen the cylinder head cover in 2-3 steps. Remove the cylinder head cover.
5. Remove the accessory drive belts, water pump pulley, timing belt covers and timing belt.
6. Remove the distributor.
7. Hold the camshaft with a wrench on the cast hexagon, and loosen the camshaft sprocket mounting bolt. Remove the camshaft sprockets.
8. Remove the seal plate.
9. Rotate the camshafts clockwise so the cams don't press on the tappets.
10. Loosen the front camshaft cap bolts in 5-6 steps, starting on the two outside bolts and finishing on the two inside bolts. Remove the front camshaft bolts and caps.

    NOTE: Note the location of the numbers on top of the camshaft caps, so the caps can be reinstalled in their original positions.

11. Loosen the camshaft cap bolts in 5-6 steps, in the reverse order of removal. Remove the camshaft caps.
12. Remove the camshafts. Remove the chain and oil seals from the camshafts.

    To install:

1.5L (Z5D) Engine

1. Insert the chain adjuster between the camshafts.
2. Lubricate the camshaft lobes and journals with clean engine oil and install the camshafts on the cylinder head. Make sure none of the lobes are located directly on the tappets. Align the marks on the camshaft gear and the timing chain.
3. Apply silicone sealant to the cylinder head on the front camshaft caps mating surface. Do not get sealant on the camshaft journals.
4. Install the camshaft bearing caps in their original locations. Hand tighten the camshaft cap bolts numbered: 5, 7, 2, and 4. Install all the bolts and tighten, in sequence, in 5-6 steps with a final torque of 100-125 inch lbs. (11-14 Nm).
5. Apply clean engine oil to the lips of new camshafts seals. Install the seals using a suitable seal installer flush with the edge of the camshaft cap.
6. Install the seal plate.
7. Install the camshaft sprockets, timing belt and timing belt covers. Install the water pump pulley and accessory drive belts. Adjust the tension.
8. Apply silicone sealant to a new cylinder head cover gasket, and install the gasket on the cylinder head cover.
9. Apply silicone sealant to the cylinder head in the area adjacent to the front camshaft caps.
10. Install the distributor.
11. Install the cylinder head cover. Tighten the bolts in 2 steps, in reverse of the loosening sequence, to 61-95 inch lbs. (7-11 Nm).
12. Install the power steering hose brackets and tighten the bolts to 88 inch lbs. (10 Nm). Connect the spark plug wires and clips.
13. Connect the breather hose and PCV valve.
14. Adjust the valve clearance.
15. Adjust the ignition timing and idle speed.
16. Connect the negative battery cable, run the engine and check for leaks.

1.8L (BPE, BPD) Engine

1. Lubricate the camshaft lobes and journals with clean engine oil and install the camshafts on the cylinder head. Make sure none of the lobes are located directly on the HLAs.
2. Apply silicone sealant to the cylinder head on the front camshaft caps mating surface. Do not get sealant on the camshaft journals.
3. Install the camshaft bearing caps in their original locations. Install all the bolts and tighten, in sequence, in 5-6 steps with a final torque of 100-125 inch lbs. (11-14 Nm).
4. Apply clean engine oil to the lips of new camshafts seals. Install the seals using a suitable seal installer flush with the edge of the camshaft cap.
5. Install the seal plate.
6. Install the camshaft sprockets, timing belt and timing belt covers. Install the water pump pulley and accessory drive belts. Adjust the tension.
7. Apply silicone sealant to a new cylinder head cover gasket, and install the gasket on the cylinder head cover.
8. Apply silicone sealant to the cylinder head in the area adjacent to the front camshaft caps.
9. Install the distributor.
10. Install the cylinder head cover. Tighten the bolts in 2 steps, in reverse of the loosening sequence, to 61-95 inch lbs. (7-11 Nm).
11. Install the power steering hose brackets and tighten the bolts to 88 inch lbs. (10 Nm). Connect the spark plug wires and clips.
12. Connect the breather hose and PCV valve.
13. Adjust the ignition timing and idle speed.
14. Connect the negative battery cable, run the engine and check for leaks.

1993-95 MX3 1.8L (K8) and 1993-97 626 and MX6 2.5L (KL) Engines

1. Relieve the fuel system pressure. Disconnect the negative battery cable.
2. Remove the intake manifold. Label and disconnect the spark plug wires from the spark plugs.
3. Remove the upper timing belt cover bolts. If removing the left cylinder head cover, disconnect the ventilation pipe from the front of the left side (front) cylinder head cover.
4. Remove the bolts, in 5-6 steps, using the reverse of the tightening sequence. Remove the cylinder head cover.
5. Remove the timing belt and the camshaft sprockets.
6. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the hydraulic lifters.
7. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right hand (rear) caps are marked with numbers and the left hand (front) caps are marked with letters.
8. Loosen the front camshaft cap bolts in sequence, in 5-6 steps. Remove the front camshaft caps.
9. Remove the remaining camshaft cap bolts in the reverse of the torque sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
10. Remove the camshafts and oil seals.

    To install:

11. Install new oil seals on the camshafts. Apply clean engine oil to the camshaft lobes, journals and supports.
12. Install the camshafts so the gear marks align.
13. Remove all oil and dirt from the mating surfaces between the front camshaft cap and the cylinder head.
14. Apply silicone sealant, at a thickness of 0.06-0.09 inch (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity and to the left cylinder head on the rear exhaust camshaft cap mating surface.
15. Install the thrust caps. Tighten the thrust cap bolts, in 5-6 steps, until the caps are fully seated on the cylinder head.
16. Install the remaining camshaft caps in their original positions. Tighten the caps, in sequence, in 5 equal steps, with the final step being 100-125 inch lbs. (11-14 Nm).
17. Apply clean engine oil to the lip of the new camshaft oil seal. Push the seal in lightly by hand. Tap the seal in evenly with a seal installer (49 F401 337A or equivalent) with a final protrusion of 0-0.02 inch (0-0.5mm).
18. Install the camshaft sprockets, timing belt and timing belt cover.
19. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
20. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps. Install a new gasket on the cylinder head.
21. Install the cylinder head cover. Tighten the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm). Tighten the upper timing cover bolts to 88 inch lbs. (10 Nm). Connect the ventilation pipe to the left side cylinder head cover.
22. Install the intake manifold.
23. Connect the negative battery cable. Run the engine and check for leaks.

1993-95 MX3 1.6L (B6-ZE), 1993-97 626 and MX6 2.0L (FS) Engines

1. Disconnect the negative battery cable.
2. Remove the power steering hose brackets from the cylinder head cover.
3. Label and disconnect the spark plug wires and spark plug wire clips.
4. Disconnect the breather tube and PCV valve from the cylinder head cover. Loosen the cylinder head cover in 2-3 steps. Remove the cylinder head cover.
5. Remove the accessory drive belts, timing belt covers and timing belt.
6. Hold the camshaft with a wrench on the cast hexagon, and loosen the camshaft sprocket mounting bolt. Remove the camshaft sprockets.
7. Note the location of the numbers on top of the camshaft caps, so the caps can be reinstalled in their original positions.
8. Loosen the camshaft cap bolts in 5-6 steps, in the reverse order of installation. Remove the camshaft caps and the oil seals.
9. Remove the camshafts.

   To install:

10. Lubricate the camshaft lobes and journals with clean engine oil and install the camshafts on the cylinder head. Make sure none of the lobes are located directly on the hydraulic lifters.
11. Apply silicone sealant to the cylinder head on the front camshaft caps mating surface. Do not get sealant on the camshaft journals.
12. Install the camshaft bearing caps in their original locations. Install the bolts and tighten, in sequence, in 5-6 steps with a final torque of 100-125 inch lbs. (11.3-14.2 Nm).
13. Apply clean engine oil to the lips of new camshafts seals. Install the seals using a suitable seal installer.
14. Install the camshaft sprockets, timing belt and timing belt covers. Install the accessory drive belts and adjust the tension.
15. Apply silicone sealant to a new cylinder head cover gasket, and install the gasket on the cylinder head cover.
16. Apply silicone sealant to the cylinder head in the area adjacent to the front camshaft caps.
17. Install the cylinder head cover. Tighten the bolts in 2 steps, in reverse of the loosening sequence, to 61-95 inch lbs. (7-11 Nm).
18. Install the power steering hose brackets and tighten the bolts to 88 inch lbs. (10 Nm). Connect the spark plug wires and clips.
19. Connect the breather hose and PCV valve.
20. Connect the negative battery cable, run the engine and check for leaks.

1993-95 929 3.0L (JE-ZE) Engines

1. Properly relieve the fuel system pressure.
2. Disconnect the negative battery cable, and drain the cooling system.
3. Remove the fresh air duct and air intake pipe.
4. Remove the cooling fan and shroud.
5. Disconnect the spark plug wires and remove the spark plugs. Remove the idler pulleys and the accessory drive belts.
6. Remove the coolant bypass hose and the upper radiator hose. Disconnect the electrical connector and remove the distributor.
7. Hold the crankshaft pulley with a suitable tool and remove the bolt. Remove the crankshaft pulley. Be careful not to damage the sensor rotor.
8. Remove the timing belt covers. Rotate the crankshaft until the camshaft and crankshaft sprocket timing marks are aligned.
9. Remove the upper idler pulley and the tensioner and pulley. Mark the direction of rotation on the timing belt and remove the timing belt.
10. Disconnect the accelerator cable. Disconnect and plug the fuel lines. Label and disconnect the necessary electrical connectors and vacuum hoses.
11. Loosen and remove the lower intake manifold bolts in 2-3 steps. Remove the lower intake manifold.
12. Remove the cylinder head covers.
13. Hold the camshaft with a wrench on the hexagon cast into the camshaft and remove the camshaft sprocket bolt. Remove the camshaft sprockets.
14. Remove bolts A from the front camshaft cap on the left cylinder head. Loosen the remaining camshaft cap bolts in 2-3 steps in sequence. Mark the position of the caps so they can be reinstalled in their original positions.
15. Remove the camshaft caps and remove the camshafts. Remove the camshaft oil seals. Label the camshafts so they can be reinstalled in their proper locations.
16. Lift out and label the rocker arms, if necessary.

    To install:

17. If removed, position the rocker arms.
18. Lubricate the camshaft lobes and journals with clean engine oil and install the camshafts on the cylinder heads. Apply clean engine oil to the lips of the new camshaft seals, if replaced, and install them on the camshafts.
19. Apply a small amount of silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow sealant to get on the camshaft journal, oil seal face or camshaft thrust face.
20. Install the camshaft caps in their original locations. Gradually tighten the cap bolts, in sequence, to 24 ft. lbs. (32 Nm). Tighten the front cap bolts, A, on the left cylinder head to 95 inch lbs. (11 Nm).
21. Hold the camshafts using a wrench on the hexagon cast into the camshaft. Install the camshaft sprockets with the retaining bolts. Tighten the sprocket bolts on the right cylinder head to 59 ft. lbs. (80 Nm) and the sprocket bolts on the left cylinder head to 19 ft. lbs. (25 Nm).
22. Apply sealant to the cylinder head in the areas adjacent to the front camshaft caps. Install the cylinder head covers and tighten the nuts to 39 inch lbs. (4 Nm).
23. Install the lower intake manifold using new gaskets. Tighten the mounting nuts in 2-3 steps, in the proper sequence, to 19 ft. lbs. (25 Nm). Connect the fuel lines.
24. Install the upper intake manifold to the lower intake manifold, using a new gasket. Tighten the bolts to 19 ft. lbs. (25 Nm).
25. Connect the electrical connectors and vacuum hoses. Connect the accelerator cable.
26. Position the timing belt tensioner on a suitable press. Place a flat washer at the bottom of the tensioner body to prevent damage to the body plug. Slowly press in the tensioner rod, but do not exceed 2200 lbs. Insert a pin in the tensioner body to hold the rod in place, then install the tensioner and tighten the mounting bolts to 19 ft. lbs. (25 Nm).
27. Make sure the crankshaft and camshaft sprocket timing marks are properly aligned. Install the timing belt over the sprockets and pulleys in the following order: crankshaft sprocket, lower idler pulley, left cylinder head exhaust cam sprocket, left cylinder head intake cam sprocket, tensioner pulley, right cylinder head exhaust cam sprocket and right cylinder head intake cam sprocket.
28. Push the belt down and install the upper idler pulley. Tighten the upper idler pulley bolt to 38 ft. lbs. (52 Nm). Make sure the camshaft and crankshaft sprocket timing marks are still aligned after installing the upper idler pulley.
29. Turn the crankshaft 2 revolutions in the normal direction of rotation and realign the timing marks. Make sure all timing marks are correctly aligned.
30. Remove the pin from the automatic tensioner and again rotate the crankshaft 2 turns. Confirm that the timing marks are aligned.
31. Install the timing belt covers and tighten the bolts to 95 inch lbs. (11 Nm).
32. Install the crankshaft pulley. Hold the pulley with a suitable tool and tighten the pulley bolt to 123 ft. lbs. (167 Nm). Be careful not to damage the sensor rotor.
33. Install the spark plugs and the distributor assembly. Connect the spark plug wires and the distributor electrical connector.
34. Install the upper radiator hose and water bypass hose. Install the idler pulleys and accessory drive belts. Adjust the belt tension.
35. Install the shroud and cooling fan. Install the air intake pipe and fresh air duct.
36. Connect the negative battery cable. Fill and bleed the cooling system.
37. Start the engine and bring to normal operating temperature. Check for leaks. Check the ignition timing and idle speed.

1995-97 Millenia 2.3L (KJS) Engines

1. Relieve the fuel system pressure. Disconnect the negative battery cable.
2. Remove the timing belt covers and timing belt.
3. Remove the spacer and O-ring from the front of the camshaft.
4. Remove the ignition coils.
5. Remove the intake manifold.
6. Remove the bolts, in 5-6 steps, using the reverse of the tightening sequence. Remove the cylinder head cover.
7. Remove the camshaft sprockets.
8. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the adjustment shims.
9. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right hand (rear) caps are marked with numbers and the left hand (front) caps are marked with letters.
10. Loosen the front camshaft cap bolts in sequence, in 5-6 steps. Remove the front camshaft caps.
11. Remove the remaining camshaft cap bolts in the proper sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
12. Remove the camshafts and oil seals.
13. If necessary, remove the lifters and adjustment shims. Identify and mark each lifter as it is removed so it can be reinstalled in the same position.

    To install:

14. Apply clean engine oil to the lifters, then install them in their original positions. Verify that they move smoothly in their bore.
15. Install new oil seals on the camshafts. Apply clean engine oil to the camshaft lobes, journals and supports.
16. Install the camshafts so the gear marks align.
17. Remove all oil and dirt from the mating surfaces between the front camshaft cap and the cylinder head.
18. Install the thrust caps. Tighten the thrust cap bolts, in 5-6 steps, until the caps are fully seated on the cylinder head.
19. Apply silicone sealant, at a thickness of 0.06-0.09 inch (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity.
20. Install the remaining camshaft caps in their original positions. Tighten the caps, in sequence, in five equal steps, with the final step being 100-125 inch lbs. (11-14 Nm).
21. Apply clean engine oil to the lip of the new camshaft oil seal. Push the seal in lightly by hand. Tap the seal in evenly with a seal installer (49 F401 337A or equivalent) with a final protrusion of 0-0.02 inch (0-0.5mm). Tap in a new blind cap.
22. Install the camshaft sprockets. Tighten the mounting bolts to 91-103 ft. lbs. (123-140 Nm).
23. Measure and adjust valve clearances.
24. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
25. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps. Install a new gasket on the cylinder head.
26. Install the cylinder head cover. Tighten the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm).
27. Using a new O-ring, install the distributor.
28. Install the ignition coils.
29. Install the intake manifold.
30. Install the spacer, using a new O-ring. Tighten the mounting bolt to 14-18 ft. lbs. (19-25 Nm).
31. Install the timing belt and timing belt cover.
32. Connect the negative battery cable. Run the engine and check for leaks.

1995-97 Millenia 2.5L (KLD) Engine

1. Relieve the fuel system pressure. Disconnect the negative battery cable.
2. Remove the timing belt covers and timing belt.
3. Remove the air cleaner housing assembly.
4. Label and disconnect the spark plug wires from the spark plugs.
5. Remove the distributor.
6. Remove the intake manifold.
7. Remove the bolts, in 5-6 steps, using the reverse of the tightening sequence. Remove the cylinder head cover.
8. Remove the camshaft sprockets.
9. Turn the camshafts so the knock pins are aligned with the marks on the camshaft caps. This will reduce the pressure on the hydraulic lifters.
10. Note the markings on the camshaft caps prior to removal, so they can be reinstalled in the same positions. The right hand (rear) caps are marked with numbers and the left hand (front) caps are marked with letters.
11. Loosen the front camshaft cap bolts in sequence, in 5-6 steps. Remove the front camshaft caps.
12. Remove the remaining camshaft cap bolts in the proper sequence. Remove the caps, being sure to remove the thrust caps last. Do not damage the cylinder head thrust bearing support.
13. Remove the camshafts and oil seals.
14. If necessary, remove the hydraulic lifters. Identify and mark each lifter 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 an oil-filled sealed container.

    To install:

15. If removed, inspect each lifter by holding it in your hand and pressing the bottom up against the top of the lifter. If there is movement, replace the lifter.
16. Apply clean engine oil to the lifters, then install them in their original positions. Verify that they move smoothly in their respective bores.
17. Install new oil seals on the camshafts. Apply clean engine oil to the camshaft lobes, journals and supports.
18. Install the camshafts so the gear marks align.
19. Remove all oil and dirt from the mating surfaces between the front camshaft cap and the cylinder head.
20. Install the thrust caps. Tighten the thrust cap bolts, in 5-6 steps, until the caps are fully seated on the cylinder head.
21. Apply silicone sealant, at a thickness of 0.06-0.09 inch (1.5-2.5mm), to the cylinder head surface in the area forward of the camshaft gear cavity and to the left cylinder head on the rear exhaust camshaft cap mating surface.
22. Install the remaining camshaft caps in their original positions. Tighten the caps, in sequence, in five equal steps, with the final step being 100-125 inch lbs. (11-14 Nm).
23. Apply clean engine oil to the lip of the new camshaft oil seal. Push the seal in lightly by hand. Tap the seal in evenly with a seal installer (49 F401 337A or equivalent) with a final protrusion of 0-0.02 inch (0-0.5mm).
24. Install the camshaft sprockets. Tighten the mounting bolts to 91-103 ft. lbs. (123-140 Nm).
25. Remove any sealant and gasket material from the cylinder head cover contact surfaces.
26. Apply silicone sealant to the cylinder head in the area adjacent to the front and rear camshaft caps. Install a new gasket on the cylinder head.
27. Install the cylinder head cover. Tighten the bolts in 5-6 steps, in sequence, to 44-78 inch lbs. (5-9 Nm).
28. Install the intake manifold.
29. Using a new O-ring, install the distributor.
30. Install the spark plug wires.
31. Install the air cleaner housing assembly.
32. Install the timing belt and timing belt cover.
33. Connect the negative battery cable. Run the engine and check for leaks.

1993-94 Miata 1.6L (B6E) and 1.8L (BPD) Engines

1. Disconnect the negative battery cable. Drain the cooling system.
2. Label and disconnect the spark plug wires and remove the spark plugs.
3. Disconnect the hoses from the cylinder head cover, if equipped.
4. Remove the cylinder head cover bolts and remove the cylinder head cover.
5. Remove the timing belt. Remove the crank angle sensor.
6. Hold the camshaft with a wrench on the hexagon cast into the camshaft. Remove the sprocket bolts and remove the sprockets.
7. Label the caps so they can be reinstalled in their original positions. Loosen the camshaft cap bolts in 2-3 steps in the reverse of the torque sequence, then remove the camshaft caps.
8. Remove the camshafts. Remove the camshaft oil seals from the camshafts.

   To install:

9. Lubricate the camshaft journals and lobes with clean engine oil. Install the camshafts in the cylinder head.
10. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
11. Install the camshaft caps in their original positions. Loosely install the cap bolts.
12. Tighten the camshaft cap bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.
13. Apply clean engine oil to the lip of a new camshaft seal. Push the seal slightly in by hand. Tap the seal into position, using a seal installer, until it is flush with the edge of the camshaft cap.
14. Turn the camshafts until the dowel pins face straight up. Install the camshaft sprockets and the sprocket bolts.
15. Hold the camshaft with the wrench on the cast hexagon and tighten the sprocket bolts to 44 ft. lbs. (60 Nm).
16. Install the remaining components in the reverse order of removal.

1995-97 Miata 1.8L (BPD) Engine

1. Disconnect the negative battery cable.
2. Remove the power steering hose brackets from the cylinder head cover.
3. Label and disconnect the spark plug wires and spark plug wire clips.
4. Disconnect the breather tube and PCV valve from the cylinder head cover. Loosen the cylinder head cover in 2-3 steps. Remove the cylinder head cover.
5. Remove the accessory drive belts, water pump pulley, timing belt covers and timing belt.
6. Remove the crankshaft position sensor.
7. Hold the camshaft with a wrench on the cast hexagon, and loosen the camshaft sprocket mounting bolt. Remove the camshaft sprockets.
8. Note the location of the numbers on top of the camshaft caps, so the caps can be reinstalled in their original positions.
9. Loosen the camshaft cap bolts in 5-6 steps. Remove the camshaft caps.
10. Remove the camshafts. Remove the oil seals from the camshafts.

    To install:

11. Lubricate the camshaft lobes and journals with clean engine oil and install the camshafts on the cylinder head. Make sure none of the lobes are located directly on the hydraulic lifters.
12. Apply silicone sealant to the cylinder head on the front camshaft caps mating surface. Do not get sealant on the camshaft journals.
13. Install the camshaft bearing caps in their original locations. Install the bolts and tighten, in sequence, in 5-6 steps with a final torque of 100-125 inch lbs. (11-14 Nm).
14. Apply clean engine oil to the lips of new camshafts seals. Install the seals using a suitable seal installer flush with the edge of the camshaft cap.
15. Install the camshaft position sensor. Tighten the mounting bolt to 14-18 ft. lbs. (19-25 Nm).
16. Install the camshaft sprockets, timing belt and timing belt covers. Install the water pump pulley and accessory drive belts. Adjust the tension.
17. Apply silicone sealant to a new cylinder head cover gasket, and install the gasket on the cylinder head cover.
18. Apply silicone sealant to the cylinder head in the area adjacent to the front camshaft caps.
19. Install the cylinder head cover. Tighten the bolts to 44-78 inch lbs. (5.0-8.8 Nm).
20. Install the power steering hose brackets and tighten the bolts to 88 inch lbs. (10 Nm). Connect the spark plug wires and clips.
21. Connect the breather hose and PCV valve.
22. Connect the negative battery cable, run the engine and check for leaks.