CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly Click here.

PROCEDURE


  1. INSTALL NO. 2 CAMSHAFT BEARING

    Click here

  2. INSTALL NO. 1 CAMSHAFT BEARING

    Click here

  3. INSTALL OIL CONTROL VALVE FILTER

    Click here

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the No. 2 camshaft in a vise by clamping the hexagonal part using aluminum plates.

      Note

      Do not damage the No. 2 camshaft by tightening the vise excessively.

    2. A01W0E5E03
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

      Align and insert the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.

    3. A01VZE4E46
      Text in Illustration
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

    4. B001O0J

      Secure the camshaft timing exhaust gear assembly with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft timing exhaust gear assembly Click here.

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01W31UE02
      Text in Illustration
      *a Timing Notch

      Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover sub-assembly are aligned.

  6. INSTALL NO. 2 CAMSHAFT


    1. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

      A01W01WE03
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and bearing caps.

    4. A01W3YNE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Hold up the chain sub-assembly and align the timing mark and the paint mark, and install the No. 2 camshaft.

      Tech Tips


      • "A" is not a timing mark.

      • Perform "Inspection After Repair" after replacing the No. 2 camshaft Click here.

  7. INSTALL CAMSHAFT


    1. Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

      A01W01WE02
      Text in Illustration
      *A Type A *B Type B
      *1 No. 1 Valve Rocker Arm Sub-assembly *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap - -

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and bearing caps.

    4. A01W0ILE04
      Text in Illustration
      *1 Knock Pin
      *a Approximately 17°

      Install the camshaft to the camshaft housing sub-assembly as shown in the illustration.

      Tech Tips

      Perform "Inspection After Repair" after replacing the camshaft Click here.

  8. INSTALL CAMSHAFT BEARING CAP


    1. A01VZAL

      Confirm the marks and numbers on the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them in their proper positions and directions.

    2. B001NUXE08

      Using several steps, uniformly tighten the 10 bolts in the sequence shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A01W2DSE08

      Using several steps, uniformly tighten the 11 bolts in the sequence shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check the torque of each bolt again.

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01VZEWE03
      Text in Illustration
      *a Advance Position
      *b Retard Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the camshaft timing gear assembly.

    2. A01W15IE01
      Text in Illustration
      *a Narrow
      *b Wide

      Install the camshaft timing gear assembly as shown in the illustration.

    3. A01W4PDE01
      Text in Illustration
      *a Narrow
      *b Wide

      Turn the camshaft timing gear assembly approximately 180° counterclockwise.

    4. A01W3GPE06
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Align the paint mark with the timing mark and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      "A" is not a timing mark.

    5. A01W22RE04
      Text in Illustration
      *1 Knock Pin
      *a Knock Pin Hole

      Align and insert the knock pin of the camshaft with the pin hole of the camshaft timing gear assembly.

    6. A01VZE4E46
      Text in Illustration
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    7. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    8. If the lock pin has not been released, release it.


      1. A01VZZBE05
        Text in Illustration
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        After cleaning and degreasing the intake side VVT oil hole on the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)

      3. A01W5JY

        Apply approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the hole made in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach the adhesive tape.

        • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

      4. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        Tech Tips


        • Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

      5. Remove the adhesive tape from the No. 1 camshaft bearing cap.

    9. A01W1FG

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

    10. A01W34FE02
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration.

      Tech Tips


      • "A" is not a timing mark.

      • Perform "Inspection After Repair" after replacing the camshaft timing gear assembly Click here.

  10. ADD ENGINE OIL

    Click here

  11. INSTALL TIMING CHAIN GUIDE

    Click here

  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01W440E02

      Turn the crankshaft pulley approximately 10° clockwise.

    2. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Make sure not to drop the gasket inside the timing chain cover sub-assembly.

    3. Remove the pin from the stopper plate.

  13. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Turn the crankshaft pulley until its timing notch (groove) and the timing mark "0" of the timing chain cover sub-assembly are aligned.

      A01W41OE02
      Text in Illustration
      *a Timing Mark *b Timing Notch
      *c Approximately 7° *d Approximately 32°

    2. Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  14. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  15. INSTALL TIMING CHAIN COVER TIGHT PLUG

    Click here

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  17. INSTALL IGNITION COIL ASSEMBLY

    Click here

  18. CONNECT ENGINE WIRE


    1. Install the engine wire to the engine with the 3 bolts and 4 nuts.

      A01W3JBE02
      Torque:
      Nut A
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 12 connectors and 5 clamps.

    3. Engage the 2 claws to connect the inlet heater water hose and outlet heater water hose A.

  19. INSTALL NO. 2 ENGINE ROOM RELAY BLOCK (for LHD)


    1. Install the No. 2 engine room relay block with the bolt and 2 clamps.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Install the front fender liner RH with the screw.

  20. INSTALL ENGINE MOVING CONTROL ROD BRACKET

    Click here

  21. INSTALL EARTH WIRE

    Click here

  22. INSTALL NO. 2 ENGINE MOUNTING STAY RH

    Click here

  23. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  24. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  25. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  26. INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

  27. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

  29. INSPECT FOR OIL LEAK

  30. INSTALL FRONT FENDER APRON SEAL RH

  31. INSTALL ENGINE UNDER COVER RH

  32. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH

  33. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  34. INSTALL FRONT WHEEL RH

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }