CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the camshaft, No. 2 camshaft or camshaft timing gear assembly.


PROCEDURE


  1. INSTALL NO. 2 CAMSHAFT BEARING

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  2. INSTALL NO. 1 CAMSHAFT BEARING

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  3. INSTALL OIL CONTROL VALVE FILTER

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  4. INSTALL CAMSHAFT TIMING SPROCKET


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

      Note

      Do not damage the No. 2 camshaft.

    2. Install the camshaft timing sprocket to the No. 2 camshaft with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

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

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A0001BCC06
      *a Timing Mark "0"
      *b Timing Mark (Groove)

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

  6. INSTALL NO. 2 CAMSHAFT

    Tech Tips

    Perform "Inspection After Repairs" after replacing the No. 2 camshaft.



    1. A0000T4C21
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housings and camshaft bearing caps.

    4. A0000ULC05
      *a Paint Mark
      *b Timing Mark

      Hold up the chain sub-assembly, align the timing mark and paint mark and install the No. 2 camshaft.

  7. INSTALL CAMSHAFT

    Tech Tips

    Perform "Inspection After Repairs" after replacing the camshaft.



    1. A0000T4C21
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housings and camshaft bearing caps.

    4. A0000TZC06
      *1 Knock Pin
      *a Approximately 17°

      Install the camshaft to the camshaft housing sub-assembly as shown in the illustration.

  8. INSTALL CAMSHAFT BEARING CAP


    1. A0001ZR

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    2. A00014JN05

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

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. A00011CN05

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

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check the torque of each bearing cap bolt again.

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly.



    1. A0001VFC32
      *a Advanced Position
      *b Retarded Position
      *c Alignment Mark
      *d Knock Pin Hole

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the camshaft timing gear assembly.

    2. A0002APC05
      *a Narrow
      *b Wide

      Install the camshaft timing gear assembly as shown in the illustration.

    3. A0001V1C05
      *a Narrow
      *b Wide

      Turn the camshaft timing gear assembly approximately 180° counterclockwise.

    4. A0000SHC06
      *a Paint Mark
      *b Timing Mark

      Align the paint mark with the timing mark to install the chain sub-assembly.

    5. A0002AEC65
      *1 Knock Pin
      *a Knock Pin Hole

      Align and attach the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly.

    6. A0000BLC91
      *1 Camshaft Timing Gear Assembly
      *a INCORRECT
      *b CORRECT
      *c Clearance
      *d No Clearance
      *e Camshaft Flange

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

    7. Secure the camshaft in place by hand, and then install the bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    8. If the lock pin has not been released, release it.


      1. A00017EC05
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        After cleaning and degreasing the intake side VVT oil hole on the camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

        Note

        Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Make a hole in the adhesive tape covering the oil hole as shown in the illustration. (Procedure A)

      3. A0000DV

        Apply approximately 200 kPa (2.0 kgf/ cm2, 29 psi) of air pressure to the hole made in procedure A to release the lock pin.

        Note


        • If air leaks out, reattach the adhesive tape.

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

      4. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        Tech Tips

        Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

      5. Remove the adhesive tape from the camshaft bearing cap.

    9. A00009WC02
      *a Hold
      *b Turn

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

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

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

    10. A0001JCC06
      *a Paint Mark
      *b Timing Mark

      Check that each timing mark of the camshaft timing gear assembly and camshaft timing sprocket are aligned with each timing mark located as shown in the illustration.

  10. ADD ENGINE OIL

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  11. INSTALL TIMING CHAIN GUIDE

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  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A0001V4C06
      *a Approximately 10°

      Turn the crankshaft approximately 10° clockwise.

    2. Install a new gasket and the No. 1 chain tensioner with the 2 bolts.

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

      Note

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

    3. Remove the pin from the stopper plate.

  13. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


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

      A00004TC03
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) *d Timing Mark "0"

    2. Check that the timing marks of the camshaft timing gear assembly and camshaft timing sprocket are 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" in the illustration is not a timing mark.

  14. INSTALL TIMING CHAIN COVER PLATE

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  15. INSTALL TIMING CHAIN COVER TIGHT PLUG

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  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  17. INSTALL IGNITION COIL ASSEMBLY

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  18. CONNECT ENGINE WIRE


    1. Connect the engine wire to the engine with the 7 bolts and 3 nuts.

      A0002BIC04
      *a Bolt A *b Bolt B
      *c Bolt C *d Bolt D
      *e Nut - -
      Torque:
      for bolt A
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
      for bolt B and nut
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }
      for bolt C
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt D
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Connect the 17 connectors and 2 clamps.

  19. CONNECT GROUND WIRE

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  20. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  21. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  22. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  23. INSTALL FAN AND GENERATOR V BELT

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  24. CONNECT RADIATOR RESERVOIR ASSEMBLY

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  25. INSTALL SERVICE PLUG GRIP

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  26. INSPECT FOR OIL LEAK

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  27. INSTALL REAR ENGINE UNDER COVER RH

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  28. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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  29. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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