CAMSHAFT REMOVAL

PROCEDURE

1. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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2. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

   

   
   

   1. Remove the air cleaner filter element.

3. REMOVE NO. 1 IGNITION COIL

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4. DISCONNECT DUTY VACUUM SWITCHING VALVE

   

   
   

   1. Remove the bolt and disconnect the duty vacuum switching valve.

5. DISCONNECT VENTILATION HOSE

   

   
   

   1. Disconnect the ventilation hose from the ventilation valve.

6. SEPARATE WIRE HARNESS

   
   

   1. Separate the wire harness from the cylinder head cover.

7. REMOVE WIRE HARNESS CLAMP BRACKET

   

   
   

   1. Remove the bolt and wire harness clamp bracket.

8. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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9. REMOVE TIGHT PLUG

   
   
   1. 

      Text in Illustration

      *1	8 mm Socket Hexagon Wrench

      Using an 8 mm socket hexagon wrench, remove the tight plug.

10. REMOVE CAMSHAFT TIMING GEAR

    
    

    1. 

       Text in Illustration

       *a	Timing Mark

       Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing mark of timing chain cover (Set the No. 1 piston to the TDC/ exhaust).

    2. Make sure that the timing mark of the camshaft sprocket is at the top.

       Tech Tips

       If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark comes to the top (Set the No. 1 piston to the TDC/exhaust).

    3. 

       Text in Illustration

       *a	Paint Mark
       *b	Timing Mark

       Place paint marks on the chain plate corresponding to the timing marks of the camshaft timing gear and the camshaft timing sprocket.

    4. Rotate the crankshaft 90° clockwise.

       Note

       Do not allow the lifted valve and piston to come into contact with each other when removing the camshaft.

    5. 

       Text in Illustration

       *a	Hold
       *b	Turn

       Loosen the bolts on the camshaft timing sprocket while holding the hexagonal portion of the camshaft.

    6. 

       Text in Illustration

       *1	Stopper Plate
       *2	Plunger

       Insert a screwdriver from the plug hole and turn the stopper plate of the timing chain tensioner clockwise to release the lock, and keep it as it is.

       Tech Tips

       
       

       • The plunger of the timing chain tensioner is locked.

       • If the stopper plate is locked firmly, slightly turn the hexagonal portion of the camshaft to the right and left.

    7. 

       Text in Illustration

       *1

       Plunger

       Slightly turn the hexagonal portion of the camshaft clockwise so that the plunger of the timing chain tensioner is pushed by the timing chain.

    8. 

       Text in Illustration

       *1	Hexagon Wrench

       Insert the hexagon wrench into the stopper plate hole.

       Tech Tips

       Hold the hexagon wrench with tape so that the hexagon wrench does not come off.

    9. 

       Text in Illustration

       *a	Hold
       *b	Turn

       Remove the bolt of the camshaft timing gear while holding the hexagonal portion of the No. 2 camshaft.

    10. 

        Remove the camshaft timing gear.

11. REMOVE CAMSHAFT

    
    

    1. 

       Slide the camshaft timing sprocket toward the engine front until the No. 1 camshaft bearing cap comes off.

    2. 

       Text in Illustration

       *1	No. 1 Camshaft Bearing Cap
       *2	No. 2 Camshaft Bearing Cap

       Remove the 15 bolts in the order shown in the illustration.

    3. Remove the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps.

    4. 

       Remove the camshaft.

       Tech Tips

       
       

       • Remove the camshaft along with the camshaft timing sprocket.

       • Assemble the camshaft timing sprocket to the camshaft before installing them.

12. REMOVE NO. 2 CAMSHAFT

    
    

    1. Remove the No. 2 camshaft.

    2. 

       Using a piece of string or the equivalent, fix the timing chain to prevent it from dropping.

13. REMOVE CAMSHAFT TIMING SPROCKET ASSEMBLY

    
    

    1. Remove the bolt and camshaft timing sprocket.