CAMSHAFT REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

      A01EOAJE02
      Text in Illustration
      *1 Crankshaft Timing Gear Key *2 Timing Mark
      *a Toward Ceiling *b Timing Mark Position
      *c Knock Pin Position *d Approximately 2°
      *e Approximately 45° *f Approximately 16°
      *g Approximately 18° *h Approximately 32°

  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH


    1. A01ERPRE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

    2. A01ENERE02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Hexagon Wrench

      Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.

    3. A01EPB2

      Remove the 2 bolts, No. 1 chain tensioner LH and gasket.

  4. REMOVE CHAIN TENSIONER SLIPPER LH

    A01ENMQ

  5. REMOVE NO. 1 CHAIN VIBRATION DAMPER LH


    1. A01EP74

      Remove the 2 bolts and No. 1 chain vibration damper LH.

  6. REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH


    1. A01EOIIE02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *3 No. 3 Chain Tensioner
      *a Push

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

    2. A01ENWRE02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. A01EON7E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing exhaust gear.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  7. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01EQ88

      Remove the 2 bolts and No. 3 chain tensioner.

  8. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH


    1. A01EON4E02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

    2. A01EPJ3E02
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Hexagon Wrench

      Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.

    3. A01ERAW

      Remove the 2 bolts and No. 1 chain tensioner RH.

  9. REMOVE CHAIN TENSIONER SLIPPER RH

    A01ENRQ

  10. REMOVE NO. 1 CHAIN VIBRATION DAMPER RH


    1. A01ESCG

      Remove the 2 bolts and No. 1 chain vibration damper RH.

  11. REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH


    1. A01EPC8E02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *3 No. 2 Chain Tensioner
      *a Push

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

    2. A01ERP3E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing gear.

    3. A01ER65E02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

      Note


      • Be careful not to damage the cylinder head with the wrench.

      • Do not disassemble the camshaft timing exhaust gear.

    4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

    5. Remove the No. 1 and No. 2 chains from the gears.

  12. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01EQ3O

      Remove the 2 bolts and No. 2 chain tensioner.

  13. REMOVE CAMSHAFT BEARING CAP LH


    1. A01EO2HE02
      Text in Illustration
      *A for Intake Side
      *B for Exhaust Side
      *1 Knock Pin

      Make sure that the knock pins of the camshafts are positioned as shown in the illustration.

    2. A01EQ2OE01

      Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

    3. A01EQHFE01

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 6 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  14. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 3 camshaft from the camshaft housing LH.

  15. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 4 camshaft from the camshaft housing LH.

  16. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01ENGLE01
      Text in Illustration
      *1 Protective Tape

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

      Tech Tips

      Tape the screwdriver tip before use.

  17. REMOVE CAMSHAFT BEARING CAP RH


    1. A01EPHJE02
      Text in Illustration
      *A for Exhaust Side
      *B for Intake Side
      *1 Knock Pin

      Make sure that the knock pins of the camshafts are positioned as shown in the illustration.

    2. A01EQ1SE05

      Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

    3. A01EPT7E04

      Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 6 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  18. REMOVE NO. 1 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 1 camshaft from the camshaft housing RH.

  19. REMOVE NO. 2 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 2 camshaft from the camshaft housing RH.

  20. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01ESERE01
      Text in Illustration
      *1 Protective Tape

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

      Tech Tips

      Tape the screwdriver tip before use.

  21. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Install the camshaft bearing cap Click here.

      Tech Tips

      Only install the intake camshaft.

    2. Install the camshaft housing Click here.

      Tech Tips

      Do not use seal packing when installing the camshaft housing as the installation is temporary.

    3. Apply a light coat of engine oil to the camshaft and camshaft timing gear.

    4. A01ENOHE06

      Using the hexagonal portion of the camshaft, align the knock pin of the camshaft with the pin hole of the camshaft timing gear and install the camshaft timing gear.

      Text in Illustration
      *1 Knock Pin
      *2 Pin Hole

      Note


      • Do not forcefully push on the camshaft timing gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear.

      • A01EREWE08

        Do not loosen or remove the 3 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing gear assembly with a new one.

      Text in Illustration
      *1 Flange Bolt
      *2 Straight Pin
      *a Do not remove

    5. Apply a light coat of engine oil to the threads and under the head of the bolt.

    6. A01EMUCE02
      Text in Illustration
      *a Hold
      A01EO1M Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear flange bolt.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    7. Remove the camshaft bearing cap Click here.

    8. Check the lock of the camshaft timing gear.


      1. Clamp the camshaft in a vise and confirm that the camshaft timing gear is locked.

        Note

        Be careful not to damage the camshaft.

    9. A01EPW5E04
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *a Open
      *b Close
      A01EPFF Vinyl Tape

      Release the lock pin.


      1. Clean the cam journal with non-residue solvent.

      2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

      3. Break through the tape over the advance side path. Then break through the tape over the retard side path on the opposite side of the advanced side path as shown in the illustration.

      4. A01EOGUE02
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

        Apply compressed air at approximately 200 kPa (2.0 kgf/cm2, 29 psi) to the two paths accessible through the holes in the tape.

        Note

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

      5. A01EQEQE02
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Decompress
        *b Hold Pressure

        Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.

        Tech Tips

        This operation releases the lock pin which holds the timing gear in the most retarded position.

      6. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path in that order.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    10. Check for smooth rotation.


      1. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not use air pressure to perform the smooth rotation check.

    11. Check the lock at the most retarded position.


      1. Confirm that the camshaft timing gear becomes locked at the most retarded position.

    12. Install the camshaft bearing cap Click here.

      Tech Tips

      Only install the intake camshaft.

    13. Install the camshaft housing Click here.

      Tech Tips

      Do not use seal packing when installing the camshaft housing as the installation is temporary.

    14. A01ENGFE02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

    15. Remove the camshaft bearing cap Click here.

    16. Remove the flange bolt and camshaft timing gear.

  22. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Install the camshaft bearing cap Click here.

      Tech Tips

      Only install the exhaust camshaft.

    2. Install the camshaft housing Click here.

      Tech Tips

      Do not use seal packing when installing the camshaft housing as the installation is temporary.

    3. Apply a light coat of engine oil to the camshaft and camshaft timing exhaust gear.

    4. A01EN6EE07

      Using the hexagonal portion of the camshaft, align the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear and install the camshaft timing exhaust gear.

      Text in Illustration
      *1 Pin Hole
      *2 Knock Pin

      Note


      • Do not forcefully push on the camshaft timing exhaust gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear.

      • A01EROGE07

        Do not loosen or remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the camshaft timing exhaust gear assembly with a new one.

      Text in Illustration
      *1 Flange Bolt
      *a Do not remove

    5. Apply a light coat of engine oil to the threads and under the head of the bolt.

    6. A01EPMVE02
      Text in Illustration
      *a Hold
      A01EO1M Turn

      Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear flange bolt.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    7. Remove the camshaft bearing cap Click here.

    8. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear is locked.

    9. A01EQ7RE06
      Text in Illustration
      *1 Advance Side Path
      *2 Retard Side Path
      *a Open
      *b Close
      A01EPFF Vinyl Tape

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

      2. Break through the tape over the advance side path. Then break through the tape over the retard side path on the opposite side of the advanced side path as shown in the illustration.

      3. A01EQV5E03
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path

        Apply compressed air at approximately 200 kPa (2.0 kgf/cm2, 29 psi) to the two paths accessible through the holes in the tape (the advance side path and retard side path).

        Note

        Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.

      4. A01ESOXE04
        Text in Illustration
        *1 Advance Side Path
        *2 Retard Side Path
        *a Hold Pressure
        *b Decompress

        Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.

      5. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts.

    10. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position, due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    11. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear becomes locked at the most advanced position.

    12. Install the camshaft bearing cap Click here.

      Tech Tips

      Only install the exhaust camshaft.

    13. Install the camshaft housing Click here.

      Tech Tips

      Do not use seal packing when installing the camshaft housing as the installation is temporary.

    14. A01EQJGE02
      Text in Illustration
      *a Hold
      A01EO1M Turn

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

    15. Remove the camshaft bearing cap Click here.

    16. Remove the flange bolt and camshaft timing exhaust gear.