CAMSHAFT REMOVAL

PROCEDURE

1. REMOVE SERVICE PLUG GRIP

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2. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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3. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

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4. REMOVE REAR ENGINE UNDER COVER RH

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5. REMOVE FAN AND GENERATOR V BELT

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6. DISCONNECT RADIATOR RESERVOIR ASSEMBLY

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7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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8. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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9. REMOVE AIR CLEANER CASE SUB-ASSEMBLY

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10. DISCONNECT GROUND WIRE

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11. DISCONNECT ENGINE WIRE

    
    

    1. Disconnect the 17 connectors and 2 clamps.

       

    2. Remove the 7 bolts and 3 nuts and disconnect the engine wire from the engine.

12. REMOVE IGNITION COIL ASSEMBLY

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13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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14. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    
    
    1. 

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

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

    2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing sprocket 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 sprocket.

15. REMOVE TIMING CHAIN COVER PLATE

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16. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    
    

    1. 

       *a	Approximately 10°

       Turn the crankshaft approximately 10° clockwise.

    2. 

       *a	Approximately 10°

       Turn the crankshaft approximately 10° counterclockwise.

    3. 

       *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. 

       *a	Approximately 10°

       Turn the crankshaft 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 assembly.

    6. 

       *a	Approximately 10°

       Turn the crankshaft approximately 10° counterclockwise.

17. REMOVE TIMING CHAIN GUIDE

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18. REMOVE TIMING CHAIN COVER TIGHT PLUG

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19. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    
    

    1. 

       *a	Hold
       *b	Turn

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

       Note

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

    2. 

       Separate the camshaft timing gear assembly from the camshaft.

    3. 

       *a	Narrow
       *b	Wide

       Remove 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.

20. REMOVE CAMSHAFT BEARING CAP

    
    

    1. 

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

    2. 

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

    3. Remove the 5 camshaft bearing caps.

       Tech Tips

       Arrange the removed parts in the correct order.

21. REMOVE CAMSHAFT

    
    

    1. 

       Remove the camshaft from the camshaft housing sub-assembly.

22. REMOVE NO. 2 CAMSHAFT

    
    

    1. 

       Hold up the chain 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 assembly.

23. REMOVE CAMSHAFT TIMING SPROCKET

    
    

    1. Secure the No. 2 camshaft between aluminum plates in a vise.

       Note

       Do not damage the No. 2 camshaft.

    2. 

       Remove the bolt and camshaft timing sprocket.

       Note

       Be careful not to damage the No. 2 camshaft and camshaft timing sprocket.

24. REMOVE OIL CONTROL VALVE FILTER

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25. REMOVE NO. 1 CAMSHAFT BEARING

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26. REMOVE NO. 2 CAMSHAFT BEARING

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