CAMSHAFT REMOVAL

PROCEDURE


  1. REMOVE FAN SHROUD

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  2. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  3. REMOVE VENTILATION HOSE


    1. A01MW6W

      Detach the clamp.

    2. Slide the clip and remove the ventilation hose from the cylinder head cover sub-assembly.

  4. REMOVE NO. 4 VENTILATION HOSE


    1. A01MV14

      Slide the 2 clips and remove the No. 4 ventilation hose from the cylinder head cover sub-assembly and inlet compressor elbow.

  5. REMOVE IGNITION COIL ASSEMBLY

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  6. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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  7. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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  8. DISCONNECT ENGINE WIRE


    1. A01MWV9

      Detach the clamp and disconnect the No. 3 ventilation hose from the engine wire.

    2. Disconnect the air fuel ratio sensor connector.

    3. Remove the bolt and disconnect the engine wire from the cylinder head cover sub-assembly.

  9. REMOVE NO. 1 TURBO WATER PIPE


    1. A001JM9C01
      *1 No. 1 Turbo Water By-pass Hose
      *2 No. 2 Turbo Water By-pass Hose
      *3 No. 3 Turbo Water By-pass Hose
      *4 No. 4 Turbo Water By-pass Hose
      *5 No. 1 Turbo Water Pipe

      Slide the 4 clips and disconnect the No. 1, No. 2, No. 3 and No. 4 turbo water by-pass hoses.

    2. Remove the 3 bolts and No. 1 turbo water pipe.

  10. REMOVE NO. 3 VENTILATION HOSE


    1. A01MX2J

      Slide the clip and disconnect the No. 3 ventilation hose from the cylinder head cover sub-assembly.

  11. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01MWKW

      Remove the 19 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

  12. REMOVE CYLINDER HEAD COVER GASKET


    1. A001HZAC01
      *1 Cylinder Head Cover Gasket
      *2 No. 2 Cylinder Head Cover Gasket

      Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket from the cylinder head cover sub-assembly.

  13. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET


    1. A001KWNC01
      *1 Camshaft Bearing Cap Oil Hole Gasket
      *2 Gasket

      Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

    2. Remove the gasket from the No. 2 camshaft bearing cap.

  14. REMOVE VACUUM PUMP ASSEMBLY

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  15. REMOVE CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

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  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A001I6LC01
      *a Paint Mark
      *b Timing Mark (Groove)
      *c Timing Mark "0"

      Turn the crankshaft until the timing mark (groove) of the crankshaft pulley assembly and the timing mark "0" of the timing chain cover assembly are aligned.

    2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

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

  17. REMOVE TIMING CHAIN COVER PLATE

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  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A001HO5C01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    2. A001HK7C01
      *a Approximately 15°

      Turn the crankshaft approximately 15° counterclockwise.

    3. A001I6CC01
      *a Stopper Plate
      *b Pin

      Align the holes of the stopper plate and No. 1 chain tensioner assembly, and insert a pin into the stopper plate hole to lock the No. 1 chain tensioner assembly.

    4. A001HO5C01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    5. A001J2YC01
      B003WAF Bolt
      B003U82 Nut

      Remove the bolt and nut, and then remove the No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

      Note

      Make sure not to drop the gasket inside the timing chain cover assembly.

    6. A001HK7C01
      *a Approximately 15°

      Turn the crankshaft approximately 15° counterclockwise.

  19. REMOVE TIMING CHAIN GUIDE

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  20. REMOVE CAMSHAFT TIMING GEAR BOLT


    1. A001LFFC01
      *a Hold
      B003WAF Turn

      Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing gear bolt from the camshaft.

      Note

      Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

  21. REMOVE CAMSHAFT BEARING CAP


    1. A001IBXN03

      Using several steps, remove the 11 camshaft bearing cap bolts in the sequence shown in the illustration.

    2. A001KLWN02

      Using several steps, remove the 10 camshaft bearing cap bolts in the sequence shown in the illustration.

      Note

      Make sure to loosen the camshaft bearing cap bolts evenly while holding the camshaft horizontally.

    3. Remove the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps from the camshaft housing sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  22. REMOVE CAMSHAFT


    1. A01MYK6

      Raise the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.

  23. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01MUIF

      Remove the camshaft timing gear assembly.

      Note

      Do not disassemble the camshaft timing gear assembly.

  24. REMOVE NO. 2 CAMSHAFT


    1. A01MWF0

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

    2. A01MW3U

      Suspend the chain sub-assembly with a string or equivalent as shown in the illustration.

      Note

      Be careful not to drop the chain sub-assembly inside the timing chain cover assembly.

  25. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A001KWDC05
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the No. 2 camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. A01MUL3

      Remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

      Note


      • Be careful not to damage the No. 2 camshaft and camshaft timing exhaust gear assembly.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  26. REMOVE OIL CONTROL VALVE FILTER

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  27. REMOVE NO. 1 CAMSHAFT BEARING

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  28. REMOVE NO. 2 CAMSHAFT BEARING

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  29. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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