Camshaft Install

Camshaft Install

An upgraded camshaft can positively impact performance and negatively impact fuel efficiency!! The selection of camshaft for your engine is always a trade off between horsepower and torque. I selected Tomei's Poncam Set (260° duration, 11.2mm lift) because they were the only ones that I could find that are specifically for the S15 SR20DE and didn't require any valve train upgrade. The larger cams that are available require uprated valve springs and, in some cases, a hydraulic lash adjuster killer kit. Tomei also claims that the valves are optimally timed and won't require further tuning - not that I believe that.

Unfortunately I wasn't able to take any pictures during my installation, however process is quite simple and outlined below.

Requirements

Basic automotive tools
27mm wrench (spanner) and 24mm wrench (spanner)
27mm Socket and a long ratchet or breaker bar
Big screwdriver or small prybar
Torque wrench (low range)
Timing light
Liquid gasket such as permatex orange
Vice or press to compress the timing chain tensioner
Camshafts
Valve (rocker cover) gaskets (there are two of them, one for the outer edge and one for the spark plug orifices)
Oil filter and engine oil - always good to change the oil after replacing the camshaft)

1.	Don't jack the car up yet, it will make your life much easier if you remove the rocker cover first! Remove the air intake pipe that runs above the radiator and disconnect all the the spark plug wires and other connectors in the vicinity of the rocker cover. Disconnect all of the hoses to the rocker cover and then loosen the rocker cover bolts as shown in the diagram. Remove the rocker cover itself and the rocker cover gasket and remove all traces of jointing or liquid gasket from the 3 half moon shaped sections of the cylinder head. when removing hoses and wires, it is often a good idea to use some masking tape and a pen to help remember where to reinstall them. Similarly I often use sandwich bags to put the bolts and parts that I remove into, and mark the bags with a permanent market to help find them again!
2.	Jack the car up and support it properly. Using the 27mm socket rotate the crankshaft so that number 1 cylinder is at top dead center (TDC). This is done by aligning the timing marks (grooves in the crankshaft pulley) with the needle that comes out of it. There are about 6 timing marks on the pulley, the second from the left is the correct one (on my S15 this was marked with yellow paint). If you find it difficult to see the timing marks, removing the fan shroud will make it easier (see Underdrive pulley installation instructions for removing the shroud). If you are using the smaller pulley, make sure your line of site to between the needle and the timing marks is straight downwards and not at an angle)
3.	Remove front cover for intake pulley and clean off the jointing compound/liquid gasket that may be there.
	Remove the cover of the distributor cap and, using either paint, a scribe or similar tool (I used a sharpened nail) mark the rotor (grey rotating bit) and the distributor body at the same point so that you will be able to realign them later. Turbo models have a camshaft position sensor, in this case it is best to leave the sensor in place and mark it against the side of the cylinder head so that you can ensure that it remains in alignment. Check the position of the mating marks (indented marks on the front face of the camshaft sprockets. The easiest way is to look sideways onto the sprocket from level with the top of the cylinder head and count the number of sprocket teeth you can see. The exhaust camshaft should have 9 visible teeth to the mating mark, the intake camshaft should have 5.
	Timing chain tensioner
	Loosen camshaft sprockets but don't remove
	Camshaft brackets, oil tubes and baffle plate
	Camshaft sprockets

to be continued