CAMSHAFT REMOVAL

PROCEDURE


  1. REMOVE INVERTER WITH CONVERTER ASSEMBLY

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  2. REMOVE ECM

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  3. REMOVE FUEL PUMP ASSEMBLY

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  4. REMOVE NO. 1 ENGINE COVER

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  5. REMOVE INJECTOR DRIVER

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  6. REMOVE ENGINE COVER

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  7. REMOVE PCV VALVE SUB-ASSEMBLY

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  8. DISCONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A000T6I

      Remove the bolt and disconnect the No. 2 water by-pass pipe.

  9. REMOVE IGNITION COIL ASSEMBLY

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  10. REMOVE SPARK PLUG

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  11. REMOVE NO. 2 OIL LEVEL DIPSTICK GUIDE

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  12. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover LH.

    2. A000QUB

      Remove the 16 bolts, cylinder head cover LH and gasket.

    3. A000T69

      Remove the 5 gaskets.

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Detach the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover.

    2. A000RKY

      Remove the 15 bolts, cylinder head cover and gasket.

    3. A000PYB

      Remove the 5 gaskets.

  14. REMOVE SPARK PLUG TUBE GASKET

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  15. REMOVE TIMING CHAIN COVER PLATE


    1. A000P57

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

  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A000NWZ

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

    2. A000RU9E03
      Text in Illustration
      *A for Bank 2
      *B for Bank 1
      *1 Paint Mark
      *2 Timing 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 chain in alignment with the timing marks on each camshaft timing gear and bearing cap.

      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.

  17. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000QLWE09

      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. A000RLSE12
      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. A000NWZ

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

    4. A000O88

      Remove the 2 bolts and No. 1 chain tensioner.

      Note

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

  18. SEPARATE CHAIN SUB-ASSEMBLY


    1. A000S52E09

      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.

      Tech Tips

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

    2. A000SMTE02
      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.

      Tech Tips

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

    3. A000QVB

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

  19. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A000MVFE01
      Text in Illustration
      *1 Service Bolt and Washers (used to temporarily secure the camshaft housing)
      *a Part to be removed
      *b Install the service bolts and washers to temporarily secure the camshaft housing

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

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

      • Do not allow the service bolts and washers to contact the camshaft.

      • Do not drop the service bolts and washers into the cylinder head.

      Tech Tips


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

      • Part number for the service bolts used to temporarily secure the camshaft housing: 91551-F0850 (9 bolts)

      • Part number for the service washers used to temporarily secure the camshaft housing: 90201-12028 (18 washers)

  20. REMOVE NO. 2 CAMSHAFT


    1. A000NLP

      Remove the bolt of the No. 2 chain tensioner.

    2. A000QJG

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

    3. A000QK6

      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.

  21. REMOVE CAMSHAFT


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

    2. A000N2M

      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. A000NAB

      Suspend the chain with a string or equivalent.

  22. SEPARATE CHAIN SUB-ASSEMBLY


    1. A000NWZ

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

    2. A000S20

      Remove the chain from the sprocket of the camshaft timing gear and set it on the camshaft timing 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 2)


    1. A000SH9E01
      Text in Illustration
      *1 Service Bolt and Washers (used to temporarily secure the camshaft housing)
      *a Part to be removed
      *b Install the service bolts and washers to temporarily secure the camshaft housing

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

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

      • Do not allow the service bolts and washers to contact the camshaft.

      • Do not drop the service bolts and washers into the cylinder head.

      Tech Tips


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

      • Part number for the service bolts used to temporarily secure the camshaft housing: 91551-F0850 (8 bolts)

      • Part number for the service washers used to temporarily secure the camshaft housing: 90201-12028 (16 washers)

  24. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. A000ON6

      Remove the bolt of the No. 3 chain tensioner.

    2. A000OYW

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

    3. A000RVG

      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.

  25. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


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

    2. A000S4C

      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. A000SUN

      Suspend the chain with a string or equivalent.

  26. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


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


      1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

    2. A000OEEE26
      Text in Illustration
      *1 Advanced Side Path
      *2 Retard Side Path
      *a Open
      *b Close
      B002BZV Rubber
      B002BPS Vinyl Tape

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration.

      3. A000RDGE08
        Text in Illustration
        *1 Advanced Side Path
        *2 Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths.

        CAUTION:

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

      4. A000OW8E20
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Hold Pressure
        *b Decompress

        Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.

        Tech Tips

        This operation releases the lock pin at the most retarded position.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and next from the advance side path.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    3. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not use air pressure to perform the smooth operation check.

    4. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

    5. A000NAYE01
      Text in Illustration
      *1 Flange Bolt
      *2 Straight Pin
      *a Do Not Remove

      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.

  27. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Check the camshaft timing exhaust gear lock.


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

    2. A000QBPE20
      Text in Illustration
      *1 Advanced Side Path
      *2 Retard Side Path
      *a Open
      *b Close
      B002BZV Rubber
      B002BPS Vinyl Tape

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft groove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path as shown in the illustration.

      3. A000P9LE04
        Text in Illustration
        *1 Advanced Side Path
        *2 Retard Side Path

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path).

        CAUTION:

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

      4. A000SPFE16
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Hold Pressure
        *b Decompress

        Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure first from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    3. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    4. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

    5. A000ORZE06
      Text in Illustration
      *1 Flange Bolt
      *2 Straight Pin
      *a Do Not Remove

      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.