CAMSHAFT REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed, installed, or replaced during the camshaft removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative when not Performed Link

  • Replacement of camshaft

  • Replacement of No. 2 camshaft

  • Replacement of No. 3 camshaft sub-assembly

  • Replacement of No. 4 camshaft sub-assembly

  • Replacement of camshaft timing gear assembly

Inspection after repair Poor idle, engine start etc.

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CAUTION:

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

B003P7U

PROCEDURE


  1. REMOVE FAN SHROUD

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  2. REMOVE INTAKE AIR SURGE TANK

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  3. REMOVE NO. 1 FUEL PIPE SUB-ASSEMBLY AND NO. 2 FUEL PIPE SUB-ASSEMBLY

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  4. REMOVE IGNITION COIL ASSEMBLY

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  5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  7. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B003MIO

      Turn the crankshaft pulley, and align the notch with timing mark 0 of the timing chain cover sub-assembly.

    2. B003LG7C01
      *A for Bank 1
      *B for Bank 2
      *a Timing Mark

      Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

      If the timing marks are not aligned, turn the crankshaft 1 complete revolution (360°) and align the timing marks as described above.

    3. B003PAJC01
      *a Paint Mark
      *b Timing Mark

      Place paint marks on the No. 1 chain sub-assembly links that correspond with the timing marks of the camshaft timing gears.

  8. REMOVE TIMING CHAIN COVER PLATE


    1. B003N0W

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

  9. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  10. REMOVE NO. 2 CAMSHAFT

    Note

    As the thrust clearance of the No. 2 camshaft is small, the camshaft must be kept level while it is being removed. If the No. 2 camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the No. 2 camshaft to seize or break. To avoid this, make sure the following steps are carried out.


    1. B003OIKC01
      *a Raise

      While raising the No. 2 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the No. 2 chain tensioner assembly in place.

    2. B003R0I

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt.

      Note

      Do not damage the surrounding parts.

    3. Separate the camshaft timing sprocket from the No. 2 camshaft.

    4. B003K68

      Rotate the No. 2 camshaft counterclockwise and set it as shown in the illustration.

    5. B003PYMN01

      Uniformly loosen the 8 bolts in several steps in the sequence shown in the illustration and remove the bolts.

    6. Remove the 4 camshaft bearing caps and No. 2 camshaft.

  11. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003O1C

      Remove the bolt, No. 2 chain tensioner assembly and camshaft timing sprocket.

  12. REMOVE CAMSHAFT

    Note

    As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, make sure the following steps are carried out.


    1. B003NEY

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

      Note


      • Do not damage the surrounding parts.

      • Do not disassemble the camshaft timing gear assembly.

    2. B003JCPC01
      B003R2S Slide

      Slide the camshaft timing gear assembly and separate the chain sub-assembly from the camshaft timing gear assembly.

    3. B003L1L

      Rotate the camshaft counterclockwise and set it as shown in the illustration.

    4. B003OHON01

      Uniformly loosen the 8 bolts in several steps in the sequence shown in the illustration and remove the bolts.

    5. Remove the 4 camshaft bearing caps.

    6. B003O0D

      Remove the bolt with the camshaft lifted up, and then remove the camshaft and camshaft timing gear assembly together with the No. 2 chain sub-assembly.

    7. B003S8Q

      Tie the chain sub-assembly with a string as shown in the illustration.

      Note

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

  13. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

    Note

    As the thrust clearance of the No. 4 camshaft sub-assembly is small, the No. 4 camshaft sub-assembly must be kept level while it is being removed. If the No. 4 camshaft sub-assembly is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the No. 4 camshaft sub-assembly to seize or break. To avoid this, make sure the following steps are carried out.


    1. B003PCDC01
      *a Push

      While pushing down the No. 3 chain tensioner assembly, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the No. 3 chain tensioner assembly in place.

    2. B003QBV

      Hold the hexagonal portion of the No. 4 camshaft sub-assembly with a wrench and remove the bolt.

      Note

      Do not damage the surrounding parts.

    3. Separate the camshaft timing sprocket from the No. 4 camshaft sub-assembly.

    4. B003NIBN01

      Uniformly loosen the 8 bolts in several steps in the sequence shown in the illustration and remove the bolts.

    5. Remove the 4 camshaft bearing caps and No. 4 camshaft sub-assembly.

  14. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003NVR

      Remove the bolt, No. 3 chain tensioner assembly and camshaft timing sprocket.

  15. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

    Note

    As the thrust clearance of the No. 3 camshaft sub-assembly is small, the No. 3 camshaft sub-assembly must be kept level while it is being removed. If the No. 3 camshaft sub-assembly is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the No. 3 camshaft sub-assembly to seize or break. To avoid this, make sure the following steps are carried out.


    1. B003PTU

      Release the chain tension between the camshaft timing gear assembly (for bank 2) and crankshaft timing sprocket by turning the crankshaft counterclockwise slightly.

    2. B003LTS

      Hold the hexagonal portion of the No. 3 camshaft sub-assembly with a wrench and loosen the bolt.

      Note


      • Do not damage the surrounding parts.

      • Do not disassemble the camshaft timing gear assembly.

    3. B003M34C01
      B003R2S Slide

      Slide the camshaft timing gear assembly and separate the chain sub-assembly from the camshaft timing gear assembly.

    4. B003PJYN01

      Uniformly loosen the 8 bolts in several steps in the sequence shown in the illustration and remove the bolts.

    5. Remove the 4 camshaft bearing caps.

    6. B003PG6

      Remove the bolt with the No. 3 camshaft sub-assembly lifted up, and then remove the No. 3 camshaft sub-assembly and camshaft timing gear assembly together with the No. 2 chain sub-assembly.

    7. B003MXH

      Tie the chain sub-assembly with a string as shown in the illustration.

      Note

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

  16. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

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