CAMSHAFT REMOVAL


  1. REMOVE FAN SHROUD

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  2. REMOVE INTAKE AIR SURGE TANK

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  3. REMOVE AIR TUBE (w/ Secondary Air Injection System)


    1. A015BGZ

      Remove the 2 bolts, 2 nuts and air tube.

    2. Remove the 2 gaskets.

      Note

      Be careful not to damage the installation surface of the gaskets.

  4. REMOVE NO. 2 AIR TUBE (w/ Secondary Air Injection System)


    1. A015D72

      Remove the 2 bolts, 2 nuts and No. 2 air tube.

    2. Remove the 2 gaskets.

      Note

      Be careful not to damage the installation surface of the gaskets.

  5. REMOVE NO. 1 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. A015646

      Disconnect the No. 1 emission control valve set connector.

    2. Disconnect the No. 1 air hose from the No. 1 emission control valve set.

    3. A0156S8

      Remove the 3 nuts and No. 1 emission control valve set.

  6. REMOVE NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. A01571M

      Disconnect the No. 2 emission control valve set connector.

    2. Disconnect the No. 3 air hose.

    3. A015BUD

      Remove the 3 nuts and No. 2 emission control valve set.

  7. REMOVE IGNITION COIL ASSEMBLY


    1. A015CK2E01
      Text in Illustration
      *A Bank 1
      *B Bank 2

      Disconnect the 6 ignition coil connectors.

    2. Remove the 6 bolts and 6 ignition coils.

  8. DISCONNECT VANE PUMP ASSEMBLY


    1. A015904

      Disconnect the connector.

    2. Detach the wire harness clamp.

    3. A015A9Q

      Remove the 2 bolts and disconnect the vane pump.

  9. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A0155ZG

      Remove the 2 bolts and 2 No. 2 idler pulleys.

  10. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A015B2D

      Remove the 3 bolts and heat insulator.

  11. REMOVE GENERATOR ASSEMBLY


    1. A015C5L

      Disconnect the generator connector.

    2. Open the terminal cap.

    3. Remove the nut and disconnect the generator wire from terminal B.

    4. Remove the bolt and disconnect the wire harness clamp bracket.

    5. A015AA8

      Remove the bolt and disconnect the generator bracket.

    6. A0159AY

      Remove the 2 bolts and generator.

    7. A015BB0

      Remove the bolt and generator bracket.

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0159L2

      Remove the engine oil level dipstick.

    2. Remove the bolt and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  13. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A015DJZ

      Disconnect the 2 hoses.

    2. Remove the 3 bolts and water by-pass pipe.

  14. REMOVE NO. 1 OIL PIPE


    1. A015A9D

      Remove the 2 oil pipe unions, oil control valve filter LH, 3 gaskets and No. 1 oil pipe.

      Note

      Do not touch the mesh when removing the oil control valve filter.

  15. REMOVE NO. 2 OIL PIPE


    1. A0156GL

      Remove the 2 oil pipe unions, oil control valve filter RH, 3 gaskets and No. 2 oil pipe.

      Note

      Do not touch the mesh when removing the oil control valve filter.

  16. DISCONNECT FUEL PIPE SUB-ASSEMBLY


    1. Remove the 2 bolts and disconnect the fuel pipe.

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. A0155GA

      Remove the 12 bolts, seal washer, cylinder head cover and gasket.

      Tech Tips

      Make sure the removed parts are returned to the same places they were removed from.

    2. A01554J

      Remove the 3 gaskets.

  18. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A015CWY

      Remove the 12 bolts, seal washer, cylinder head cover and gasket.

      Tech Tips

      Make sure the removed parts are returned to the same places they were removed from.

    2. A015BEL

      Remove the 3 gaskets.

  19. REMOVE TIMING CHAIN COVER PLATE


    1. A015AAN

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

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A015DBNE01

      Turn the crankshaft pulley and align the notch with the "0" timing mark of the timing chain cover.

    2. A0159MQE01
      Text in Illustration
      *A for Bank 2
      *B for Bank 1
      *1 Paint Mark

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

      Tech Tips

      If the marks are not aligned, turn the crankshaft again to align the marks.

    3. Place paint marks on the timing marks and sprockets of each camshaft timing gear and on the links of the No. 1 chain.

      Tech Tips

      Be sure to place the paint marks on 2 links of the chain and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.

  21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01557ME01

      Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain.

      Tech Tips

      This prevents the valves and pistons from interfering with each other.

    2. A015CBUE01
      Text in Illustration
      *1 Lever Hole
      *2 Tensioner Hole

      Align the hole in the lever of the tensioner with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.27 mm (0.0500 in.) into the hole.

    3. Turn the crankshaft clockwise and align the notch with the "0" timing mark of the timing chain cover.

    4. A015D63

      Remove the 2 bolts and chain tensioner.

      Note

      Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover.

  22. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 1)


    1. A0158FQE01

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain between the banks.

      CAUTION:

      As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears.

      Note

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. A0157TUE05
      Text in Illustration
      *a 5° to 10°

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain can be removed easily.

      Note

      When turning the crankshaft, engine oil may spray out of the oil holes.

    3. A015E6D

      Remove the chain from the sprocket of the camshaft timing gear and set it on the gear.

      CAUTION:

      As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.

  23. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A015CPYE01
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Part Removal
      *b Installation of Bolts and Washers for Temporary Installation of Camshaft Housing

      Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing a bearing cap, install bolts and washers for temporary installation of the camshaft housing in the order shown in the illustration.

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

      Note


      • Do not install the bearing caps when installing bolts and washers for temporary installation of the camshaft housing.

      • Be sure to follow the numerical order when performing this procedure.

      • Do not allow bolts and washers for temporary installation of the camshaft housing to contact the camshaft.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

      Tech Tips


      • Arrange the removed parts so that they can be reinstalled in their original locations.

      • Part number of bolt for temporary installation of camshaft housing: 91551-G0845 (quantity: 8)

      • Part number of washer for temporary installation of camshaft housing: 90201-12028 (quantity: 16)

  24. REMOVE NO. 2 CAMSHAFT


    1. A0157R0

      Remove the bolt of the No. 2 chain tensioner assembly.

    2. A015AF4

      Remove the No. 2 chain tensioner assembly while lifting up the No. 2 camshaft.

    3. A0156TQ

      While lifting up the No. 2 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.

  25. REMOVE CAMSHAFT


    1. Lift up the rear of the camshaft so that it is at an angle.

    2. A015A4E

      Remove the chain from the camshaft timing gear and pull out the camshaft and No. 2 chain towards the rear of the vehicle to remove them.

      Note

      Do not drop the chain into the gap between the engine and cover.

    3. A01563R

      Suspend the chain with a string or equivalent.

  26. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 2)


    1. Turn the crankshaft counterclockwise and align the notch with the "0" timing mark of the timing chain cover.

    2. A0158JT

      Remove the chain from the sprocket of the camshaft timing gear and set it on the gear.

      CAUTION:

      As the camshaft may turn suddenly and pinch your fingers when the chain is removed, pinch the chain and lift it upward to remove it from the sprocket.

  27. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A0157SCE01
      Text in Illustration
      *1 Bolt
      *2 Washer
      *a Part Removal
      *b Installation of Bolts and Washers for Temporary Installation of Camshaft Housing

      Remove the bolts and bearing caps in the order shown in the illustration. Immediately after removing a bearing cap, install bolts and washers for temporary installation of the camshaft housing in the order shown in the illustration.

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

      Note


      • Do not install the bearing caps when installing bolts and washers for temporary installation of the camshaft housing.

      • Be sure to follow the numerical order when performing this procedure.

      • Do not allow bolts and washers for temporary installation of the camshaft housing to contact the camshaft.

      • Do not drop bolts and washers for temporary installation of the camshaft housing into the cylinder head.

      Tech Tips


      • Arrange the removed parts so that they can be reinstalled in their original locations.

      • Part number of bolt for temporary installation of camshaft housing: 91551-G0845 (quantity: 8)

      • Part number of washer for temporary installation of camshaft housing: 90201-12028 (quantity: 16)

  28. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. A015DV2

      Remove the bolt of the No. 3 chain tensioner assembly.

    2. A015DGP

      Remove the No. 3 chain tensioner assembly while lifting up the No. 4 camshaft.

    3. A015E74

      While lifting up the No. 4 camshaft, pass it through the No. 2 chain and pull it out towards the front of the vehicle to remove it.

  29. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. A015BA4

      Lift up the rear of the camshaft so that it is at an angle.

    2. Remove the chain from the camshaft timing gear and pull out the No. 3 camshaft and No. 2 chain towards the rear of the vehicle to remove them.

      Note

      Do not drop the chain into the gap between the engine and cover.

    3. A0158YC

      Suspend the chain with a string or equivalent.

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A0159Z4E01
      Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt

      Remove the flange bolt and camshaft timing gear assembly.

      Note


      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

  31. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Fix the camshaft in place.

      Note

      Be careful not to damage the camshaft.

    2. A0155DVE01
      Text in Illustration
      *1 Do not remove
      *2 Straight Pin
      *3 Flange Bolt

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.