Has anyone had issues re-installing intake camshaft 5SFE

[dazzalec1]

I bought my son a 98 camry CSX wagon with a 2.2L 5SFE, for his first car. He pulled engine and gearbox out as it has a badly slipping clutch. Rear main seal very leaky and wrecked clutch plate. While it was out of car, I said we should check head gasket etc and con rod nuts as apparently they come loose occasionally. All work has been done as per service manual, including removal procedure of camshafts and definitely torque settings. On installation of intake camshaft, it won't turn to re-align exhaust camshaft ( even at 3NM of torque on bearing caps). It was dis-assembled and re-done many times but still no good. I've watched at least 3 other guys do this on Youtube and without even following correct procedure, they have been successful. I have also tried doing it,(supervised other attempts) but also not successful.  There is no apparent damage to head, bearing caps or camshaft but is still that tight the camshaft sprocket can be tightened to around correct torque and shaft will not turn. I have rebuilt many other engines in the past and have never had this sort of issue. Does anyone have any ideas of where to next. I would try another camshaft but the wreckers I have spoken to are not helpful - apparently its getting too old. Thanks in advance.

[ozieagle]

My first thought was that you may have mixed up the cams, or the bearing shells.

 

Herb

[dazzalec1]

G'day Herb,

Thanks for the suggestion.

I wish I could say I haven't thought of that yet. Unfortunately (for me), the bearing caps were the first thing I checked. They are marked I1 thru to I4 with a little arrow to the front of the engine from the factory, and I actually checked this before they were removed originally. It saves a bit of marking etc. and can't be mixed up easily. Also the cams can't be confused as the intake camshaft is the only one that accepts a pulley on these engines. All the bearing caps and surfaces of the cam, that runs in them, look to be in very good condition - no scores or marks. Each time the caps have been torqued (with assembly lube), and found to be tight, the removal sequence in the manual was observed and then each subsequent re-torque, the tightening sequence was followed. I am truly at a loss as it came out of the head reasonably easily. The manual mentions that the clearance tolerances are very fine. I can't put my hands on a set of feeler gauges at the moment, but wouldn't mind betting the thrust portion of the cam at the end bearing block is around 50 to a 100 thousandths of an inch. I have performed the removal/installation ritual around 7 times myself now and it gets monotonous real quick. The last time before I posted, I followed the lead of a guy on Youtube ( who positioned the knockpin at around 0 to 5 degrees ATDC of cam angle, instead of the service manual stated 80 to 115 degrees BTDC of cam angle), still no luck but the camshaft is in a better position for being neutral. I have tried it as the manual and now have tried winging it but it is disturbingly tight each time, and I'm experienced enough to not force it to turn. This is starting to do my head in, as I can't see what is the issue. Sorry for the rant. I really do appreciate any help.

Thanks Darryl

[ozieagle]

Hi Darryl,

I understand your frustration, it took me 15 months to get my MGB running properly, as one of the main jets was too big.

Back to your problem, get some plastigauge, and measure your bearing clearances. Available from Repco.

 

Herb

 

Another, unpleasant, thought is that either your cam is bent and / or the head is warped.

Edited February 9 by ozieagle

[dazzalec1]

G'day Herb,

I'll look at the manual this morning when I get a chance - I don't recall seeing any tolerances listed but I just looked where I needed to. I have considered a bent camshaft and at the time of its removal, I was kind of thinking the procedure could bend it. The install procedure seems off to the removal. But as I have said, it was all done correctly, so I technically it should be fine. The engineers who designed it know better - right? (a little bit of sarcasm).  Oh and I forgot to mention that it was running and seemed to be fine. I believe the head gasket was original and the engine looked almost untouched.

Thanks Darryl

[dazzalec1]

G'day all,

Just thought I'd post the solution to my problem. I had another set of eyes look at my issue (retired mechanic who lives 4 houses down the street), and it also had him stumped after going through removal and install of camshaft. He went home and ended up brain-storming with another mechanic friend (who loves Toyotas), and he said he had seen people install 2 washers under a head bolt and cause this issue. We checked and my son had only used 1 washer, but we found the head of the head bolt stood a few millimeters higher. Once the camshaft journal blocks were torqued down the sprocket came to rest snugly on the head bolt - wow. The new bolts are aftermarket (I have left a review for that product advising of this issue), but I have to stick to a budget, as I am bank-rolling the quick rebuild as it is his first car. So yes everything works as it should now and he can continue to re-assemble it all now.

Hope this helps someone else out down the track.