CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust 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 EXHAUST GEAR ASSEMBLY

    Tech Tips

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



    1. B00570NC02
      *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. B0059FCC02
      *a Knock Pin Hole
      *b Knock Pin

      Align the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly and attach the camshaft timing exhaust gear assembly to the No. 2 camshaft.

      Note

      Do not forcefully press the camshaft timing exhaust gear assembly. Otherwise, the tip of knock pin of the No. 2 camshaft may damage the seal surface of the camshaft timing exhaust gear assembly, leading to poor sealing.

    3. B00597UC02
      *1 Camshaft Timing Exhaust Gear Assembly
      *a Incorrect
      *b Correct
      *c No. 2 Camshaft Flange
      *d No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.

    4. Secure the No. 2 camshaft in place by hand, and then install the bolt of the camshaft timing exhaust gear assembly by hand.

    5. Tighten the bolt.

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

      Note


      • Do not damage the No. 2 camshaft and camshaft timing exhaust gear assembly.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B0058ZXC02
      *a Timing Mark "0"
      *b Timing Mark (Groove)

      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.

  6. INSTALL NO. 2 CAMSHAFT

    Note

    When turning the No. 2 camshaft with the chain sub-assembly removed, take care to prevent the piston and valve from contacting and damaging the part.

    Tech Tips

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



    1. B005AHHC43
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

    2. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

    3. B005AN0C02
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the chain sub-assembly that was put on when the chain sub-assembly was removed and the timing mark of the camshaft timing exhaust gear assembly. Then install the No. 2 camshaft and camshaft timing exhaust gear assembly.

  7. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tech Tips

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



    1. B00580FC02
      *a Paint Mark
      *b Timing Mark

      Align the paint mark of the chain sub-assembly that was put on when the chain sub-assembly was removed and the timing mark of the camshaft timing gear assembly. Then install the camshaft timing gear assembly.

      Note

      Do not disassemble the camshaft timing gear assembly.

  8. INSTALL CAMSHAFT

    Note

    When turning the camshaft with the chain sub-assembly removed, take care to prevent the piston and valve from contacting and damaging the part.

    Tech Tips

    Perform "Inspection After Repair" after replacing the camshaft.



    1. B005AHHC43
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

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

    2. Apply a light coat of engine oil to the camshaft journals and camshaft housing sub-assembly.

    3. B00573WC02
      *a Knock Pin Hole
      *b Knock Pin

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

      Note

      Do not forcefully press the camshaft timing gear assembly. Otherwise, the tip of knock pin of the camshaft may damage the seal surface of the camshaft timing gear assembly, leading to poor sealing.

    4. B00579TC02
      *1 Camshaft Timing Gear Assembly
      *a Incorrect
      *b Correct
      *c Portion A of Camshaft
      *d No Clearance

      Check that there is no clearance between the camshaft timing gear assembly and portion A of the camshaft indicated in the illustration.

  9. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT

    Note

    There are different types of camshaft timing gear bolts. Make sure to check the identification mark to determine the tightening torque.

    Identification Mark:
    Item Identification Mark
    for Type A A
    for Type B C
    B005BD3C02
    *a Identification Mark

    1. B005937

      Apply engine oil to the areas of the camshaft timing gear bolt indicated in the illustration.

    2. Temporarily install the camshaft timing gear bolt.

      Tech Tips

      When temporarily installing the camshaft timing gear bolt, make sure that it is screwed in approximately 2 threads.

  10. INSTALL CAMSHAFT BEARING CAP


    1. B0057PZN03

      Install the 10 bearing cap bolts in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    2. B0057ERN04

      Install the 11 bearing cap bolts in the order shown in the illustration.

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

  11. TIGHTEN CAMSHAFT TIMING GEAR BOLT


    1. B00596T

      Check that the chain sub-assembly is loose as shown in the illustration.

    2. B005BH0C02
      *a Hold
      B0057RX Turn

      Use a wrench to hold the hexagonal portion of the camshaft.

    3. Tighten the camshaft timing gear bolt.

      Torque:
      Type A
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }
      Type B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

      Note

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

    4. B0057J0C02
      *a Paint Mark
      *b Timing Mark

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

  12. ADD ENGINE OIL

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  13. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  14. INSTALL TIMING CHAIN GUIDE

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  15. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0057XQC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    2. Temporarily install a new gasket and the No. 1 chain tensioner assembly with the nut and bolt.

      Note

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

    3. Tighten the nut and bolt.

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

    4. Remove the pin from the stopper plate.

  16. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


    1. 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.

      B005A9CC03
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark (Groove) *d Timing Mark "0"
      *e Timing Mark *f Paint Mark

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

  17. INSTALL TIMING CHAIN COVER PLATE

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  18. INSTALL VACUUM PUMP ASSEMBLY

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  19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  20. CONNECT ENGINE WIRE


    1. Connect the engine wire with the 3 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 5 connectors.

  21. INSTALL IGNITION COIL ASSEMBLY

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  22. INSTALL NO. 3 INTERCOOLER COOLING WATER PIPE

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  23. INSTALL NO. 2 INTERCOOLER COOLING WATER PIPE


    1. Install the No. 2 intercooler cooling water pipe with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the No. 1 sub-radiator hose to the No. 2 intercooler cooling water pipe, and slide the hose clip to secure the hose.

    3. Connect the No. 1 turbo water hose to the No. 2 intercooler cooling water pipe, and slide the hose clip to secure the hose.

    4. Connect the No. 6 sub-radiator hose to the No. 2 water by-pass pipe, and slide the hose clip to secure the hose.

  24. INSTALL FAN AND GENERATOR V BELT

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  25. INSTALL REAR ENGINE UNDER COVER RH

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  26. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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  27. ADD ENGINE OIL

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  28. INSPECT ENGINE OIL LEVEL

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  29. INSPECT FOR OIL LEAK

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