Camshaft

REMOVAL & INSTALLATION

1.8L Engine

1. Disconnect the negative battery cable. Remove the air intake hose and the PCV hose.
2. Remove the valve covers and timing belt.
3. Install auto lash adjuster retainer tools MD998443 or equivalent, on the rocker arm. If this tool is not available, rubber bands may be used.
4. Remove the camshaft bearing caps but do not remove the bolts from the carrier.
5. Remove the rocker arms, rocker shafts and bearing caps from the engine as an assembly.
6. Remove the camshaft from the cylinder head.
7. Inspect the bearing journals on the camshaft for excess wear or damage. Measure the cam lobe height and compare to the desired readings. Inspect the bearing surfaces in the cylinder head. Replace any components that is damaged or shows signs of excess wear.

   Fig. 1: Exploded view of the camshaft and related components — 1.8L engine

   To install:

8. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head.
9. Align the camshaft bearing caps with the arrow mark depending on cylinder numbers and install in numerical order.
10. Apply sealer at the ends of the bearing caps and install the assembly.
11. Tigthen the bearing cap bolts in the following sequence: No. 3, No. 2, No. 1 and No. 4 to 85 inch lbs. (10 Nm).
12. Repeat the sequence increasing the torque to 15 ft. lbs. (20 Nm).
13. Install the distributor extension if it was removed.
14. Install the timing belt, valve cover and all related parts.
15. Connect the negative battery cable and check for leaks.

2.0L Engine

1990–94 VEHICLES

1. Relieve the fuel system pressure.
2. Disconnect the accelerator cable from the throttle body and position aside.
3. Remove the timing belt cover and timing belt.
4. Label and disconnect the spark plug cable.
5. Remove the center cover, breather and PCV hose.
6. Remove the rocker cover, semi-circular packing, throttle body stay, crankshaft angle sensor, both camshaft sprockets, and oil seal.
7. Loosen the bearing cap bolts in 2–3 steps. Label and remove all camshaft bearing caps.

   NOTE: If the bearing caps are difficult to remove, use a plastic hammer to gently tap the rear part of the camshaft.

8. Remove the intake and exhaust camshafts.
9. Check the camshaft journals for wear or damage. Check the cam lobes for damage. Also, check the cylinder head oil holes for clogging.

   Fig. 2: Camshaft and related components — 1990–94 2.0L engines

   To install:

10. Lubricate the camshafts with heavy engine oil and position the camshafts on the cylinder head.

    NOTE: Do not confuse the intake camshaft with the exhaust camshaft. The intake camshaft has a split on its rear end for driving the crank angle sensor.

11. Make sure the dowel pin on both camshaft sprocket ends are located on the top.
12. Install the bearing caps. Tighten the caps in sequence and in 2 or 3 steps. No. 2 and 5 caps are of the same shape. Check the markings on the caps to identify the cap number and intake/exhaust symbol. Only L (intake) or R (exhaust) is stamped on No. 1 bearing cap. Also, make sure the rocker arm is correctly mounted on the lash adjuster and the valve stem end. Tighten the retaining bolts to 15 ft. lbs. (20 Nm).
13. Apply a coating of engine oil to the oil seal. Using tool MD998307 or equivalent, press-fit the seal into the cylinder head.
14. Align the punch mark on the crank angle sensor housing with the notch in the plate. With the dowel pin on the sprocket side of the intake camshaft at top, install the crank angle sensor on the cylinder head.

    NOTE: Do not position the crank angle sensor with the punch mark positioned opposite the notch; this position will result in incorrect fuel injection and ignition timing.

15. Install the timing belt, valve cover and all related parts.
16. Connect the negative battery cable and check for leaks.

1995–98 NON-TURBO ENGINES

1. Disconnect the negative battery cable.
2. Remove the ignition coil pack.
3. Disconnect the PCV hose and the breather hose from the cylinder head cover.
4. Remove the semi-circular packing from the rear of the head.
5. Remove the camshaft position sensor.
6. Remove the timing belt.
7. Use tool MB990767 and MB998719 or equivalent to hold the camshaft sprockets and remove the sprocket mounting bolt and the sprocket.
8. Remove the bracket and the rear timing belt cover.
9. Remove the outside camshaft bearing cap.
10. Gradually loosen the camshaft bearing caps in sequence, one camshaft at a time and remove the bearing caps.

    Fig. 3: Camshaft bearing cap bolt removal sequence — 1995–98 2.0L non-turbo engine

    NOTE: Keep the bearing caps in order. They must be installed in the location that they were removed from.

11. Mark the camshafts for later identification and remove the camshafts. The camshafts are not interchangeable.

    Fig. 4: Exploded view of the camshafts and related components — 1995–98 2.0L non-turbo engine

    To install:

12. Apply engine oil or assembly lube to the camshaft and install the camshafts.
13. Install the bearing caps. Torque the bolts evenly and in sequence.

    Fig. 5: Camshaft bearing cap bolt installation sequence — 1995–98 2.0L non-turbo engine

14. Apply Loctite 518® to the outside camshaft bearing caps and install them.
15. Install the camshaft oil seal.
16. Install the rear timing belt cover and the bracket.
17. Use the special tools and install the camshaft sprockets.
18. Install the timing belt.
19. Apply Loctite 5699® or equivalent to the semi-circular packing and install it in the rear of the cylinder head.
20. Install the camshaft position sensor.
21. Install the cylinder head cover. Torque the bolts in the proper sequence, evenly as follows:
    1. Step 1: 3.3 ft. lbs. (4.5 Nm).
    2. Step 2: 6.6 ft. lbs. (9.0 Nm).
    3. Step 3: 8.9 ft. lbs. (12 Nm).

       Fig. 6: Cylinder head cover bolt installation sequence — 1995–98 non-turbo engine

22. Install the air, breather and PCV hoses.
23. Install the coil pack.
24. Connect the negative battery cable.

1995–98 TURBO ENGINES

1. Disconnect the negative battery cable.
2. Disconnect the accelerator cable from the throttle body and remove the cable bracket from the intake plenum.
3. Remove the engine center cover.
4. Disconnect the spark plug cables from the spark plugs. Label them if necessary.
5. Disconnect the breather hose and the PCV hose from the rocker cover.
6. Remove the rocker cover.
7. Position the No. 1 cylinder at TDC on compression.
8. Remove the timing belt.
9. Use a wrench on the hex shaped part of the camshaft to hold the cam and remove the camshaft sprockets.
10. Loosen the bearing cap bolts in two or three steps and remove the bearing caps. If the bearing caps are hard to remove, tap the rear of the camshaft with a plastic hammer.

    Fig. 7: Tap the camshaft with a plastic hammer to loosen the bearing caps — 1995–98 2.0L turbo engine

11. Remove the camshaft(s) and the oil seals.

    Fig. 8: Exploded view of the camshafts and related components — 1995–98 2.0L turbo engines

    To install:

12. Apply engine oil or assembly lube to the camshafts and install them on the cylinder head.

    Fig. 9: During installation, make sure not to confuse the intake and exhaust camshafts

    WARNING
    If new camshaft(s) are being installed, remove the rocker arms and install the camshaft(s) and the bearing caps. Make sure the camshaft(s) can be turned by hand. After checking, remove the camshafts and install the rocker arms.

    Fig. 10: Position the camshafts with the dowels facing up — 1995–98 2.0L turbo engine

    NOTE: Bearing caps and rocker arms must be installed in the same location that they were remove from.

13. Install the bearing caps and torque the bolts evenly in two or three steps to specifications.
14. Apply engine oil to the lip of the seal. Using MB998713, install the front oil seal.
15. Install the camshaft sprockets.
16. Install the timing belt.
17. Apply sealant to the semi-circular packing and install it in the cylinder head.
18. Apply sealant to the lower part of the front and rear bearing caps where they meet the cylinder head. Use a new gasket and install the rocker cover.
19. Connect the PCV hose and the breather hose.
20. Connect the spark plug wires.
21. Install the center cover.
22. Install the adjust the accelerator cable.
23. Connect the negative battery cable.

2.4L Engines

1. Disconnect and remove the battery.
2. Remove the accelerator cable bracket and position the cable aside.
3. Remove the air intake hose.
4. Remove the breather hose and disconnect the PCV hose.
5. Label and disconnect the spark plug cables.
6. Remove the rocker cover.
7. Install lash adjuster retainer tools MD998443 or equivalent, to the rocker arm.
8. Remove the timing belt covers and the timing belt assembly.
9. While holding camshaft stationary, with an appropriate spanner wrench, remove the camshaft sprocket retainer bolt. Remove the sprocket from the shaft.
10. Remove the camshaft oil seal.
11. Remove both rocker arm shaft assemblies from the head. Do not disassembly rocker arms and rocker arm shaft assemblies.
12. Remove the camshaft from the cylinder head.
13. Inspect the bearing journals on the camshaft, cylinder head, and bearing caps.

    Fig. 11: Exploded view of the camshafts and related components — 2.4L engines

    To install:

14. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head.
15. Install the rocker arm and shaft assemblies. Tighten the rocker arm shaft retainer bolts to 21–25 ft. lbs. (29–35 Nm).
16. Apply a coating of engine oil to the oil seal. Using the proper size driver, press-fit the seal into the cylinder head.

    Fig. 12: Installation of the camshaft oil seal using the proper tool — 2.4L engines

17. Install the camshaft sprocket and retainer bolt and tighten to 65 ft. lbs. (90 Nm).
18. Install the timing belt and belt covers.
19. Remove the lash adjuster retaining tools.
20. Install the rocker cover using new gasket material on mating surfaces.
21. Connect the spark plug cables.
22. Reinstall the air intake hose.
23. Install the breather hose and connect the PCV hose.
24. Install the battery.
25. Run the engine at idle until normal operating temperature is reached. Check idle speed and ignition timing; adjust as required.