CAMSHAFT INSTALLATION

PROCEDURE


  1. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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  2. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01XB1ZE01
      Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing gear assembly and camshaft together by aligning the pin hole and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

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

    5. A01WZAJ

      Install the flange bolt while holding the camshaft.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    6. Check the lock of the camshaft timing gear assembly.


      1. Fix the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A01X5WTE01
      Text in Illustration
      *1 Pin Hole
      *2 Straight Pin

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the pin hole and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the hole.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the advanced direction.

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

    5. A01X34X

      Install the flange bolt while holding the camshaft.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

  5. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Check that the notch is aligned with the "0" timing mark of the timing chain cover.

    2. A01X1BQE09
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

    3. Clean the camshaft housing LH and camshaft journals and apply engine oil to them.

    4. A01XAR2E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    5. A01X9TME05
      Text in Illustration
      *a Place on camshaft timing gear

      Install the chain to the No. 3 camshaft, and then install the camshaft to the camshaft housing LH.

      Tech Tips


      • Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.

      • Install the camshaft so that the timing mark is facing upward.

  6. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Clean the camshaft housing LH and camshaft journals and apply engine oil to them.

    2. A01X2VAE01
      Text in Illustration
      *1 Mark Plate (yellow)
      *2 Timing Mark

      Pass the No. 4 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

      Tech Tips

      The mark plate is yellow.

    3. A01X5G4

      While lifting up the No. 4 camshaft, pass the No. 3 chain tensioner assembly through the No. 2 chain and set it in place.

    4. Install the No. 4 camshaft to the camshaft housing LH, and then install the No. 3 chain tensioner assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  7. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. A01XAR2E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    3. A01XABKE04
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Installation of Bolts and Washers for Temporary Installation of Camshaft Housing
      *b Part Installation
      B001XPG Bolt A
      A01X4WG Bolt B

      Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the bolts and washers for temporary installation of the camshaft housing in the location for a bearing cap, install the bearing cap with the bolts in the order shown in the illustration.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


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

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

    4. Check the torque of each bolt again.

  8. CONNECT CHAIN SUB-ASSEMBLY (for Bank 2)


    1. A01X1WXE01
      Text in Illustration
      *1 Paint Mark

      Align the paint marks on the camshaft timing gear and No. 1 chain and install the No. 1 chain to the camshaft timing gear.

      Tech Tips

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  9. INSTALL CAMSHAFT


    1. A01WZIGE02
      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 installed easily.

      Note

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

    2. A01X7R5E08
      Text in Illustration
      *1 Timing Mark
      *2 Mark Plate (yellow)
      *a Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear as shown in the illustration and install the No. 2 chain to the camshaft timing gear.

    3. Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

    4. A01XAR2E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    5. A01X11IE05
      Text in Illustration
      *a Place on camshaft timing gear

      Install the chain to the camshaft, and then install the camshaft to the camshaft housing RH.

      Tech Tips


      • Place the chain on the camshaft timing gear but do not engage the teeth of the sprocket and the chain.

      • Install the camshaft so that the timing mark is facing upward.

  10. INSTALL NO. 2 CAMSHAFT


    1. Clean the camshaft housing RH and camshaft journals and apply engine oil to them.

    2. A01XAO0E04
      Text in Illustration
      *1 Mark Plate (yellow)
      *2 Timing Mark

      Pass the No. 2 camshaft through the No. 2 chain from the front of the vehicle, align the mark plate (yellow) with the timing mark and install the No. 2 chain to the camshaft timing exhaust gear.

      Tech Tips

      The mark plate is yellow.

    3. A01X5AN

      While lifting up the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain and set it in place.

    4. Install the No. 2 camshaft to the camshaft housing RH, and then install the No. 2 chain tensioner assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  11. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Clean the camshaft bearing caps and apply engine oil to them.

    2. A01XAR2E01
      Text in Illustration
      *1 Valve Rocker Arm
      *2 Lash Adjuster
      *3 Valve Stem
      *4 Valve Stem Cap

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

    3. A01X8P4E04
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Installation of Bolts and Washers for Temporary Installation of Camshaft Housing
      *b Part Installation
      B001XPG Bolt A
      A01X4WG Bolt B

      Check the marks and numbers on the camshaft bearing caps, and then remove the replacement bolts and washers in the order shown in the illustration. Immediately after removing the bolts and washers for temporary installation of the camshaft housing in the location for a bearing cap, install the bearing cap with the bolts in the order shown in the illustration.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for bolt B
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


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

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

    4. Check the torque of each bolt again.

  12. CONNECT CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A01X6E0E01
      Text in Illustration
      *1 Paint Mark

      Align the paint marks on the camshaft timing gear and No. 1 chain and install the No. 1 chain to the camshaft timing gear.

      Tech Tips

      If the paint marks are not aligned, align them by turning the camshaft slightly.

  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01XAMKE07

      Turn the crankshaft counterclockwise 30° past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

    2. Turn the crankshaft slightly to eliminate the slack in the chain.

      Tech Tips

      Make sure there is some slack in the chain around the area where the chain tensioner is installed.

    3. A01X6KDE01
      Text in Illustration
      *1 Stopper Plate
      *a Push

      While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

    4. While turning the stopper plate of the tensioner counterclockwise, insert a pin with a diameter of 1.27 mm (0.0500 in.) into the holes in the stopper plate and tensioner to fix the stopper plate in place.

    5. Install the chain tensioner with the 2 bolts.

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

    6. Remove the pin from the No. 1 chain tensioner.

  14. INSPECT VALVE TIMING


    1. Check the camshaft timing marks.

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

    2. Check that each camshaft timing mark is positioned as shown in the illustration.

      A01X441E05
      Text in Illustration
      *1 Timing Mark - -
      *a Viewpoint - -

      Tech Tips

      for Intake Camshaft:

      Be sure to check mark A at the point when marks B, C and D are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

      A01X5TME07

    3. If the valve timing is misaligned, reinstall the timing chain.

    4. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.

  15. INSTALL TIMING CHAIN COVER PLATE


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

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  16. POUR ENGINE OIL

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  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  19. CONNECT FUEL PIPE SUB-ASSEMBLY

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  20. INSTALL NO. 2 OIL PIPE

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  21. INSTALL NO. 1 OIL PIPE

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  22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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  23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  24. INSTALL GENERATOR ASSEMBLY

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  25. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  26. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

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  27. CONNECT VANE PUMP ASSEMBLY

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  28. INSTALL IGNITION COIL ASSEMBLY

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  29. INSTALL NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

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  30. INSTALL NO. 1 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)

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  31. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)

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  32. INSTALL AIR TUBE (w/ Secondary Air Injection System)

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  33. INSTALL INTAKE AIR SURGE TANK

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  34. INSTALL FAN SHROUD

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  35. INSPECT IGNITION TIMING

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