CAMSHAFT REMOVAL

PROCEDURE

1. PRECAUTION

   Note

   After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

   Note

   When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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3. REMOVE FRONT WHEEL RH

4. REMOVE NO. 1 ENGINE UNDER COVER

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5. SEPARATE FRONT FENDER LINER RH

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6. REMOVE FRONT FENDER APRON SEAL RH

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7. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH

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8. REMOVE RADIATOR SIDE SEAL RH

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9. REMOVE COOL AIR INTAKE DUCT SEAL

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10. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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11. REMOVE INLET AIR CLEANER ASSEMBLY

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12. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

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13. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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14. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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15. REMOVE NO. 2 ENGINE MOUNTING STAY RH

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16. REMOVE ENGINE MOVING CONTROL ROD

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17. DISCONNECT ENGINE WIRE

    
    

    1. 

       Disengage the 2 claws and disconnect the inlet heater water hose and outlet heater water hose.

    2. Disconnect the 12 connectors and 5 clamps.

       

    3. Remove the 3 bolts and 4 nuts and disconnect the engine wire from the engine assembly.

18. REMOVE IGNITION COIL ASSEMBLY

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19. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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20. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    
    
    1. 

       *a	Paint Mark
       *b	Timing Mark
       *c	Timing Notch (Groove)

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

    2. Check that both timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

       Tech Tips

       "A" is not a timing mark.

    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.

21. REMOVE TIMING CHAIN COVER PLATE

    
    

    1. 

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

22. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    
    

    1. 

       Turn the crankshaft pulley approximately 10° clockwise.

    2. 

       Turn the crankshaft pulley approximately 10° counterclockwise.

    3. 

       *a	Pin
       *b	Stopper Plate

       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. 

       Turn the crankshaft pulley approximately 10° clockwise.

    5. 

       Remove the 2 bolts, No. 1 chain tensioner assembly and gasket.

       Note

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

    6. 

       Turn the crankshaft pulley approximately 10° counterclockwise.

23. REMOVE TIMING CHAIN GUIDE

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24. REMOVE TIMING CHAIN COVER TIGHT PLUG

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25. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    
    

    1. 

       *a	Hold
       *b	Turn

       Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt from the camshaft.

       Note

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

    2. 

       Separate the camshaft timing gear assembly from the camshaft.

    3. 

       *a	Narrow
       *b	Wide

       Separate the chain sub-assembly from the camshaft timing gear assembly, and turn the camshaft timing gear assembly approximately 180°.

    4. 

       Remove the camshaft timing gear assembly.

       Note

       Do not disassemble the camshaft timing gear assembly.

26. REMOVE CAMSHAFT BEARING CAP

    
    

    1. 

       Remove the 11 bolts in several steps in the order shown in the illustration.

    2. 

       Remove the 10 bolts in several steps in the order shown in the illustration.

    3. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps.

       Tech Tips

       Arrange the removed parts in the correct order.

27. REMOVE CAMSHAFT

    
    

    1. 

       Remove the camshaft from the camshaft housing sub-assembly.

28. REMOVE NO. 2 CAMSHAFT

    
    

    1. 

       Hold up the chain sub-assembly and remove the No. 2 camshaft from the camshaft housing sub-assembly.

    2. 

       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 sub-assembly.

29. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    
    

    1. Secure the No. 2 camshaft in a vise by clamping the hexagonal part between aluminum plates.

       Note

       Do not damage the No. 2 camshaft by tightening the vise excessively.

    2. 

       Remove the bolt and camshaft timing exhaust gear assembly.

       Note

       Do not disassemble the camshaft timing exhaust gear assembly.

30. REMOVE OIL CONTROL VALVE FILTER

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31. REMOVE NO. 1 CAMSHAFT BEARING

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32. REMOVE NO. 2 CAMSHAFT BEARING

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