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CAMSHAFT REMOVAL

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PROCEDURE


  1. Click here

    REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  2. Click here

    REMOVE FRONT AIR SHUTTER SEAL RH (for LHD)

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  3. Click here

    REMOVE FRONT AIR SHUTTER SEAL RH (for RHD)

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  4. Click here

    REMOVE FRONT NO. 1 VENTILATOR SEAL (for LHD)

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    REMOVE FRONT NO. 1 VENTILATOR SEAL (for RHD)

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  6. Click here

    REMOVE INNER COWL TOP TO COWL BRACE (for LHD)

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    REMOVE INNER COWL TOP TO COWL BRACE (for RHD)

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  8. Click here

    REMOVE OUTER COWL TOP PANEL (for LHD)

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    REMOVE OUTER COWL TOP PANEL (for RHD)

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  10. Click here

    REMOVE IGNITION COIL ASSEMBLY

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  11. Click here

    DISCONNECT NO. 2 VENTILATION HOSE


    1. B0045RL

      Slide the clip and disconnect the No. 2 ventilation hose from the cylinder head cover sub-assembly.

  12. Click here

    DISCONNECT ENGINE WIRE


    1. B0046HD

      Remove the 2 bolts.

    2. Disconnect the 5 connectors.

    3. Disengage the 5 clamps and disconnect the engine wire.

    4. B0045Z3

      Disconnect the connector.

    5. Remove the 2 nuts and disconnect the engine wire.

  13. Click here

    DISCONNECT INTERCOOLER RESERVE TANK ASSEMBLY


    1. B0045I1

      Remove the 3 bolts and disconnect the intercooler reserve tank assembly.

  14. Click here

    REMOVE AIR TUBE


    1. B00482F

      Disconnect the 4 hoses.

    2. Remove the 2 bolts and air tube.

  15. Click here

    REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. B0045RT

      Remove the 13 bolts, seal washer and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

  16. Click here

    REMOVE CYLINDER HEAD COVER GASKET


    1. B0045N8

      Remove the cylinder head cover gasket from the cylinder head cover sub-assembly.

  17. Click here

    SET NO. 1 CYLINDER TO TDC / COMPRESSION


    1. B0046ZBC01
      *a Timing Mark
      *b Timing Notch

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

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

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

    3. B00481FC02
      *a Paint Mark

      Place paint mark on the chain sub-assembly in alignment with the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

  18. Click here

    REMOVE SERVICE COVER


    1. B0046E4

      Remove the 5 bolts and service cover.

    2. B0045OBC01
      *a Protective Tape

      Using a screwdriver with its tip wrapped in protective tape, remove the service cover by prying between the service cover and camshaft housing sub-assembly.

      Note:

      Do not damage the contact surfaces of the service cover and camshaft housing sub-assembly.

  19. Click here

    REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. B0046I0

      Remove the 2 bolts and No. 2 chain vibration damper from the No. 1 camshaft bearing cap.

  20. Click here

    REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0045N4

      Disengage the clamp and disconnect the wire harness.

    2. Remove the 2 nuts, wire harness clamp bracket and No. 1 chain tensioner assembly.

  21. Click here

    INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B0045GFC01
      *a Do not remove

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

      Note:

      Do not remove the other 4 bolts ("TORX" bolt). If any of them is removed, replace the camshaft timing exhaust gear assembly.

    2. Hold the hexagonal portion of the camshaft with a wrench and turn it slightly counterclockwise to release the chain sub-assembly.

      Note:

      Do not turn the camshaft more than necessary.

      Tip:

      Be sure to loosen the chain sub-assembly because the camshaft timing exhaust gear assembly cannot be removed with the chain sub-assembly tensioned.

    3. Remove the camshaft timing exhaust gear assembly.

      Note:

      Keep the camshaft timing exhaust gear assembly horizontal while removing it from the No. 2 camshaft.

  22. Click here

    INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Temporarily install the camshaft timing exhaust gear assembly.


      1. B0045QLC01
        *a Straight Pin
        *b Key Groove

        Align the straight pin on the No. 2 camshaft with the key groove in the camshaft timing exhaust gear assembly and temporarily install the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.

        Note:

        • Do not install the chain sub-assembly onto the camshaft timing exhaust gear assembly in this step.


        • Do not allow the chain sub-assembly to interfere with the camshaft timing exhaust gear assembly when installing the camshaft timing exhaust gear assembly.

    2. Inspect the lock of the camshaft timing exhaust gear assembly.


      1. Check that the camshaft timing exhaust gear assembly is locked.

        If the camshaft timing exhaust gear assembly dose not operate as specified, replace it.

    3. B00462FC02
      *a Make a Hole
      *b Adhesive Tape Sealing Area
      *c Adhesive Tape

      Inspect camshaft timing exhaust gear assembly operation.

      Tip:

      If the camshaft timing exhaust gear assembly dose not operate as specified, replace it.


      1. After cleaning the exhaust 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. B0047MMC01
        *a Protective Tape

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi.) of air pressure into 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. Using a screwdriver with its tip wrapped with protective tape, forcibly turn the camshaft timing exhaust gear assembly in the retard direction (clockwise).

        Note:

        • Be sure to keep the camshaft timing exhaust gear assembly in the retard direction. If the camshaft timing exhaust gear assembly is released, it will return to the advanced position automatically due to the force from the spring.


        • Do not damage the camshaft timing exhaust gear assembly.

        Tip:

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

      5. B0046VVC02
        *a Protective Tape

        Using a screwdriver with its tip wrapped with protective tape, turn the camshaft timing exhaust gear assembly within its movable range (19°to 21°) 2 or 3 times without turning it to the most advanced position. Check that the camshaft timing exhaust gear assembly turns smoothly.

      6. Lock the camshaft timing exhaust gear assembly.

        Note:

        Check that the camshaft timing exhaust gear assembly locks at the most advanced position (the most advanced position of its movable range) and cannot be rotated any further.

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

    4. Remove the camshaft timing exhaust gear assembly.


      1. Remove the bolt and temporarily installed camshaft timing exhaust gear assembly.

  23. Click here

    INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Inspect the lock of the camshaft timing gear assembly.


      1. Check that the camshaft timing gear assembly is locked.

        If the camshaft timing gear assembly dose not operate as specified, replace it.

    2. Inspect camshaft timing gear assembly operation.

      Tip:

      If the camshaft timing gear assembly dose not operate as specified, replace it.


      1. B0045JUC02
        *a Make a Hole
        *b Adhesive Tape Sealing Area
        *c Adhesive Tape

        After cleaning 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 B)

      3. B0047U5

        Apply approximately 150 kPa (2.0 kgf/cm2, 22 psi.) of air pressure into the hole made in procedure B 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).

        Tip:

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

      5. B004652

        Turn the camshaft timing gear assembly within its movable range (26.5° to 28.5°) 2 or 3 times without turning it to the most retarded position. Check that the camshaft timing gear assembly turns smoothly.

        Note:

        • Do not lock the camshaft timing gear assembly.


        • If camshaft timing gear assembly is locked, release the lock pin again.

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

  24. Click here

    REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B00468VC01
      *a Do not remove

      While holding the hexagonal portion of the camshaft with a wrench, remove the camshaft timing exhaust gear flange bolt with SST.

      09249-37010
      Note:

      • Before removing the camshaft timing gear assembly, make sure that the lock pin has been released.

      • Do not remove the other 4 bolts ("TORX" bolt). If any of them is removed, replace the camshaft timing gear assembly.

      • If the camshaft timing gear assembly is to be reused, be sure to use it with the lock pin released.

    2. Remove the chain sub-assembly and camshaft timing gear assembly.

      Note:

      Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

    3. B0047U8

      Suspend the chain sub-assembly with a string or equivalent.

  25. Click here

    REMOVE CAMSHAFT BEARING CAP


    1. B0048B6E03

      Uniformly loosen and remove the 10 bolts in the order shown in the illustration.

      Note:

      Do not loosen the other 15 bearing cap bolts in this step.

      Tip:

      Arrange the removed parts in the correct order.

    2. B0046WEC01
      *a The removal order of the parts *b The installation order of the service bolts and spacers for temporarily tightening the camshaft housing sub-assembly
      *c Service Bolt and Spacer (Used to temporarily secure the camshaft housing sub-assembly) - -

      Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing the camshaft bearing caps, install service bolts and spacers in the order shown in the illustration.

      27 N*m 275 kgf*cm 20 ft.*lbf
      Note:

      • If the bolts are loosened all at once, FIPG on the camshaft housing sub-assembly and cylinder head sub-assembly may peel off, resulting in oil oozing. Therefore, be sure to install the service bolts and spacers to one camshaft bearing cap at a time.


      • Do not install the camshaft bearing caps when installing the service bolts and spacers.

      Tip:

      • Arrange the removed parts in the correct order.


      • Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly: 91551-G0875 (15 bolts)


      • Part number for the service spacers used to temporarily secure the camshaft housing sub-assembly: 90387-12048 (15 spacers)

  26. Click here

    REMOVE CAMSHAFT


    1. B0045PZ

      Remove the camshaft from the camshaft housing sub-assembly.

  27. Click here

    REMOVE NO. 2 CAMSHAFT


    1. B0046FY

      Remove the No. 2 camshaft from the camshaft housing sub-assembly.

  28. Click here

    REMOVE NO. 1 CAMSHAFT BEARING


    1. B0047SH

      Remove the 2 No. 1 camshaft bearings from the No. 1 camshaft bearing cap.

      Tip:

      Arrange the removed parts in the correct order.

  29. Click here

    REMOVE NO. 2 CAMSHAFT BEARING


    1. B0045MU

      Remove the 2 No. 2 camshaft bearings from the camshaft housing sub-assembly.

      Tip:

      Arrange the removed parts in the correct order.