CAMSHAFT REMOVAL

PROCEDURE


  1. REMOVE FAN SHROUD

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  2. REMOVE INTAKE AIR SURGE TANK

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  3. REMOVE AIR TUBE (w/ Secondary Air Injection System)

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  4. REMOVE NO. 2 AIR TUBE (w/ Secondary Air Injection System)

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  5. REMOVE NO. 1 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

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  6. REMOVE NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

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  7. REMOVE IGNITION COIL ASSEMBLY

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  8. DISCONNECT VANE PUMP ASSEMBLY

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  9. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY

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  10. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  11. REMOVE GENERATOR ASSEMBLY

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  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  13. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

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  14. REMOVE NO. 1 OIL PIPE

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  15. REMOVE NO. 2 OIL PIPE

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  16. DISCONNECT FUEL PIPE SUB-ASSEMBLY

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  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  19. REMOVE TIMING CHAIN COVER PLATE


    1. A01X4CG

      Remove the 4 bolts, timing chain cover plate and gasket.

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01X6ZU

      Turn the crankshaft pulley and align the notch with the "0" timing mark of the timing chain cover.

    2. A01XBKRE01
      Text in Illustration
      *A for Bank 2
      *B for Bank 1
      *1 Paint Mark

      Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

      Tech Tips

      If the marks are not aligned, turn the crankshaft again to align the marks.

    3. Place paint marks on the timing marks and sprockets of each camshaft timing gear and on the links of the No. 1 chain.

      Tech Tips

      Be sure to place the paint marks on 2 links of the chain and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.

  21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01X6X8E07

      Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain.

      Tech Tips

      This prevents the valves and pistons from interfering with each other.

    2. A01X7AEE01
      Text in Illustration
      *1 Lever Hole
      *2 Tensioner Hole

      Align the hole in the lever of the tensioner with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.27 mm (0.0500 in.) into the hole.

    3. Turn the crankshaft clockwise and align the notch with the "0" timing mark of the timing chain cover.

    4. A01X3DT

      Remove the 2 bolts and chain tensioner.

      Note

      Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover.

  22. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01WYUHE07

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain between the banks.

      CAUTION:

      As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears.

      Note

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. A01X9PVE03
      Text in Illustration
      *a 5° to 10°

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be removed easily.

      Note

      When turning the crankshaft, engine oil may spray out of the oil holes.

    3. A01X24J

      Remove the chain from the sprocket of the camshaft timing gear and set it on the gear.

      CAUTION:

      As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.

  23. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01X20EE04
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Part Removal
      *b Installation of Bolts and Washers for Temporary Installation of Camshaft Housing

      Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing a bearing cap, install bolts and washers for temporary installation of the camshaft housing in the order shown in the illustration.

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

      Note


      • Do not install the bearing caps when installing bolts and washers for temporary installation of the camshaft housing.

      • Be sure to follow the numerical order when performing this procedure.

      • Do not allow bolts and washers for temporary installation of the camshaft housing to contact the camshaft.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

      Tech Tips


      • Arrange the removed parts so that they can be reinstalled in their original locations.

      • Part number of bolt for temporary installation of camshaft housing: 91551-G0845 (quantity: 8)

      • Part number of washer for temporary installation of camshaft housing: 90201-12028 (quantity: 16)

  24. REMOVE NO. 2 CAMSHAFT


    1. A01X32T

      Remove the bolt of the No. 2 chain tensioner assembly.

    2. A01X5AN

      Remove the No. 2 chain tensioner assembly while lifting up the No. 2 camshaft.

    3. A01X7VW

      While lifting up the No. 2 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.

  25. REMOVE CAMSHAFT


    1. Lift up the rear of the camshaft so that it is at an angle.

    2. A01X1IN

      Remove the chain from the camshaft timing gear and pull out the camshaft and No. 2 chain towards the rear of the vehicle to remove them.

      Note

      Do not drop the chain into the gap between the engine and cover.

    3. A01X1CX

      Suspend the chain with a string or equivalent.

  26. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 2)


    1. Turn the crankshaft counterclockwise and align the notch with the "0" timing mark of the timing chain cover.

    2. A01X9ED

      Remove the chain from the sprocket of the camshaft timing gear and set it on the gear.

      CAUTION:

      As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.

  27. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01X8XKE04
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Part Removal
      *b Installation of Bolts and Washers for Temporary Installation of Camshaft Housing

      Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing a bearing cap, install bolts and washers for temporary installation of the camshaft housing in the order shown in the illustration.

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

      Note


      • Do not install the bearing caps when installing bolts and washers for temporary installation of the camshaft housing.

      • Be sure to follow the numerical order when performing this procedure.

      • Do not allow bolts and washers for temporary installation of the camshaft housing to contact the camshaft.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

      Tech Tips


      • Arrange the removed parts so that they can be reinstalled in their original locations.

      • Part number of bolt for temporary installation of camshaft housing: 91551-G0845 (quantity: 8)

      • Part number of washer for temporary installation of camshaft housing: 90201-12028 (quantity: 16)

  28. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. A01X8N0

      Remove the bolt of the No. 3 chain tensioner assembly.

    2. A01X5G4

      Remove the No. 3 chain tensioner assembly while lifting up the No. 4 camshaft.

    3. A01X4HH

      While lifting up the No. 4 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.

  29. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. A01X3PS

      Lift up the rear of the camshaft so that it is at an angle.

    2. Remove the chain from the camshaft timing gear and pull out the No. 3 camshaft and No. 2 chain towards the rear of the vehicle to remove them.

      Note

      Do not drop the chain into the gap between the engine and cover.

    3. A01WZRK

      Suspend the chain with a string or equivalent.

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01X0SME01
      Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt

      Remove the flange bolt and camshaft timing gear assembly.

      Note


      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

  31. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01X0EFE01
      Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.