How to Install Tomei Pon Cams KA24DE · PDF file · 2017-06-18How to Install Tomei...

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How to Install Tomei Pon Cams KA24DEThis guide can be used to replace any drop-in replacement cams.

Written By: Adrian

How to Install Tomei Pon Cams KA24DE

© 2017 www.moddit.com of 15

INTRODUCTION

The KA vs SR saga is something going on for many years. So what is with this growth in sales ofparts for KA’s? Is it the .4 liters that people seem to want over the SR? ? Cam-over instead of rockerarm? The turbo Friendly KA Compression?? Well whatever the reason, it’s nice to see a companylike Tomei accommodating the requests of performance enthusiast on both sides. It doesn’t matter ifit’s turbos or titanium exhaust, they have something for you. It’s so exciting to know that the sameguys that are building Super GT engines are also hard at work designing parts for cars like the oneswe have here in the US. With that FR Sport is happy to inform you Tomei USA has now released“PON” cams for your TURBO KA. They are that perfect choice for the builder who really wants tomaximize street power but be capable of track endeavors with success.

WARNING: When installing, this will more than likely not be a one day job. Shimming will berequired. NA motors will need cam gears to Advance cams. Cams were originally designed as dropin for turbo application. Treat as PROCAM for NA. FR Sport will do their best to stock these parts inorder to provide you with a faster solution to complete your project.

TOOLS:1" Wrench or Adjustable Crescent (1)

27mm Socket and Corresponding Ratchet (1)

24mm socket and Corresponding Ratchet (1)

10mm socket and Corresponding Rachet (1)

Torque Wrench in IN-LBS (1)

Safety Wire (1)

PARTS:Tomei Poncam Intake KA24DE (1)

Tomei Poncam Exhaust KA24DE (1)

Torco Assembly Lube (1)

Silicone Gasket Maker Compound. (1)



http://www.frsport.com/Tomei-TA301C-NS16A-PONCAM-CAMSHAFT-KA24DE-IN-270-9-8MM_p_1225910.html

http://www.frsport.com/Tomei-TA301E-NS16A-PONCAM-CAMSHAFT-KA24DE-EX-270-9-8MM_p_1225911.html

http://www.frsport.com/Torco-A550055PE-MPZ-Engine-Assembly-Lube-0-5-oz-_p_18107.html

http://www.frsport.com/Elring-UN-125-3000-RTV-Dirko-Silicone-Gasket-Maker-Compound_p_1287.html

Step 1 — Preparing to remove the valve cover

It is highly recommended that an oiland filter change be done beforeinstalling new cams. After warmingup the engine, Drain the oil in orderto help release the pressure on thefactory chain tensioner. We allowedthe oil to drain for about half beforebeginning our work.

Remove the Spark plug wires, andvalve cover from the engine. Usecaution not to drop anything into theengine.

Valve cover bolts should be all10mm hex bolts if they are OEM.



Step 2 — Set To TDC

Be sure to have your vehicle in Neutral as well as having the parking brake engaged.

Remove the Spark Plugs to eliminate resistance from the pressure being build up as you turn theengine.

Rotate the crankshaft with a 27mm socket and ratchet. TDC will be indicated when the Timinglocating pin is aligned with the 2nd marking from the left on the crank pulley.

The first and second lobe on the cams will both be facing outward from the center.

Step 3 — Loosen the Camshaft Sprockets

Place the 1" wrench on the camshaftand loosen the cam gear with a24mm socket.

If you do not have a 1" wrench, acresent wrench may be used.

LOOSEN BUT DO NOT REMOVE!!!



Step 4 — Mark the Chain Location

There will be small indentations /dimples on the chain to indicate thechains orientation. If you cannot seethe dimples due to the use of anaftermarket chain kit, then mark thelocation of the dowel pins to thelinks.

Step 5 — Lock the Chain Tensioner

There are 2 types of tentioners. Newer shoe retainer and the older unit that will need safety wire tolock it in place. Compress The tensioner and Secure it in place.

If you tensioner does not compress, you may need to remove the front cover and the tensioner.Once removed, the tensioner can be slowly compressed in a vice with the proper soft jaw to notdamage the guide surface.



Step 6 — Remove Cam Sprockets

Some engines have an upper chainguide held on my 2 bolts. This maynot we removed. Our specific builddid not have them.

removing the cam sprocket bolt andpull away from the cams. Wepersonally zip tied the chain to thecam gear to hold its location. Weused 2 per cam just to make surethe chain did not jump a tooth.



Step 7 — Removing the Chamshaft Caps

With the sprockets removed orpulled to the side, Begin to mark thecam caps. Many times they willalready be marked with and “I” or an“E” followed by a number to indicatetheir location. We like to add thatextra bit of insurance by actuallymarking them or at least removingand placing them in a container thatwill display their placement.

Me sure to loosen each bolt aboutone turn at a time to ensure there isnot extra load on one specific part ofthe camshaft causing it to fracture.

Each cam cap is machined to itscorresponding location. They mustgo back in the exact as they cameout.



Step 8 — Removing the Camshafts

There may be extensive load on rearcausing bind in the front section ofthe cams. You may need to presslightly on the rear of the cam anduse your 1” or crescent wrench toslowly rotate the cam out of itlocation.

Step 9 — Measuring shims

Each cam lobe has a bucket and shim above the valve. Remove each shim thickness individuallyand record your findings. Place shim back in its original location. These numbers will be important.

We have Supertech Cam Followers so the shims are located under the bucket itself. The OEM willbe larger units and easier to remove from the top.



Step 10 — Installing Camshafts

11) Installing the cam. Inspect cams to be clean and clear of all debris and burs. One will belabeled “IN” and the other will be labeled “EX” so be sure to note which is which. Lubricate the camcarriages where the cams sits with assembly lube. We used Torco MPZ Engine Assembly Lube. A0.5oz will be more than enough.



Step 11 — Installing Camshaft Caps

Inspect factory camshaft cap bolt. Many times these have stretched and need to be replaced. Wenormally like to see them new as time has taken its toll on them.

Evenly tighten 1/2 turn at a time on each bolt until all of the caps are snug. First at 1.4 ft-lb andthen again to 4.3 ft-lb. Then finally torque the bolts from the outside inward as shown in the diagramto 6.7 to 8.7 ft-lb.



Step 12 — Checking Valve Shim Clearance

You will need a feeler gauge tomeasure each gap between the shortpart of the came lob to the cambucket/cam follower. Themeasurement should beapproximately .010” to .012” cold.

You will more than likely need tomake some changes. You alreadyhave the values from themeasurements you did previously soyou will just have to punch in somenumbers in order to get you to whereyou need to be.

Shims are available throughFRSPORT.COM so give them a callto order. WARNING – Do not beshocked if you find the shim to notbe enough even after you havecalculated the thickness of the newshims. There are sometimes factorsthat you cannot see and you mayneed to go through the orderingprocess for a couple more shims.



Step 13 — Install Camshaft Sprocket

Initially install the gears to the camand tighten by hand. You will have torotate the cam slightly with a wrenchto line up the dowel pin. Oncealigned and fitted, check to see thatthe sprocket is fully seated againstthe cam before torquing the bolt tospec.

Always use a 26 m.m. or 1” wrenchon the cam hex to hold it in place asyou torque the cam sprocket bolts to123 to 130 ft-lb. You chain linksshould still be aligned with youroriginal makings on the links. The 2front lobes should also be facingaway from each other. As they werewith the factory set.



Step 14 — Preparing to run

Reinstall the factory upper chain guide if you choose to do so. It is not necessary per themanufacture but it’s up to you. You may now also remove the locking pin holding your tensioneropen.

Be sure to have a bit of assembly lube on each lobe for initial start up.



Step 15 — Valve Cover

Before installing the valve cover, you may want to place a bit of gasket maker on to the half mooncut outs on the front and the back of the motor. This ensures that it does not leak through anysmall crevasse there might be. If the gasket is stretched out from age and removal, please replace.Gaskets are available through FRSPORT.COM.

Torque specs for the bolts are first at 3 ft-lbs and then 6-7ft-lbs to finish off. Sequence is in thepicture.



This document was last generated on 2017-06-18 06:45:41 AM.

Step 16 — Break-in Procedures

Make sure to fill you top off your oil.Spark plugs should be installed aswell along with the the wires.

We then recommend you run thevehicle for about 15 minutes ataround 1500 – 2000 RPMs.Following that procedure you canthen drive the vehicle at a range ofRPM’s at a range no more thanabout 4000RPMs.

Tuning is recommended in ordertake advantage of the full potential ofthe cams.



How to Install Tomei Pon Cams KA24DE · PDF file · 2017-06-18How to Install Tomei...

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