CAMSHAFT INSTALLATION

PROCEDURE


  1. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. Secure the camshaft in a vise between aluminum plates.

      Note

      Be careful not to damage the camshaft in the vise.

    2. B0074KFC08
      *a Pin Hole
      *b knock Pin

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

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    3. Apply a small amount of engine oil to the threads and seating surface of the flange bolt.

    4. Install the flange bolt while holding the camshaft.

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

    5. Check the lock of the camshaft timing gear assembly.


      1. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

  2. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the camshaft in a vise between aluminum plates.

      Note

      Be careful not to damage the camshaft in the vise.

    2. B0075SDC08
      *a Pin Hole
      *b Knock Pin

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

      Note

      Be sure not to turn the camshaft timing exhaust gear assembly in the advanced direction.

    3. Apply a small amount of engine oil to the threads and seating surface of the flange bolt.

    4. Install the flange bolt while holding the camshaft.

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

    5. Check the lock of the camshaft timing exhaust gear assembly.


      1. Secure the camshaft in place and confirm that the camshaft timing gear assembly is locked.

        Note

        Be careful not to damage the camshaft.

  3. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. B0076NJC11
      *a Notch

      Confirm that the notch is aligned with the "0" timing mark of the timing chain or belt cover sub-assembly.

    2. B0072WXC06
      *a Timing Mark
      *b Mark Plate (yellow)
      *c Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.

    3. Clean and apply engine oil to the camshaft housing sub-assembly LH and No. 3 camshaft sub-assembly journals.

    4. B007582C02
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    5. B00734WC03
      *a Place chain sub-assembly onto camshaft timing gear assembly

      Install the chain sub-assembly to the No. 3 camshaft sub-assembly, and then place the No. 3 camshaft sub-assembly onto the camshaft housing sub-assembly LH.

      Tech Tips


      • Place the chain sub-assembly onto the camshaft timing gear assembly but do not engage the teeth of the sprocket with the chain sub-assembly.

      • Install the No. 3 camshaft sub-assembly so that the timing mark is facing upward.

  4. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Clean and apply engine oil to the camshaft housing sub-assembly LH and No. 4 camshaft sub-assembly journals.

    2. B0073VKC04
      *a Mark Plate (yellow)
      *b Timing Mark

      Pass the No. 4 camshaft sub-assembly through the No. 2 chain sub-assembly from the front of the engine, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly LH.

    3. B0074NS

      While lifting the No. 4 camshaft sub-assembly, pass the No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.

    4. Install the No. 4 camshaft sub-assembly to the camshaft housing sub-assembly LH, and then install the No. 3 chain tensioner assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  5. INSTALL CAMSHAFT BEARING CAP (for Bank 2)


    1. Clean and apply engine oil to the camshaft bearing caps.

    2. B007582C02
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    3. B007639C05
      *a Service Bolt and Washers (Used to temporarily secure the camshaft housing sub-assembly LH)
      *b Remove the service bolts and washers used to temporarily secure the camshaft housing sub-assembly LH
      *c Part to be installed
      B0073AQ Bolt (A)
      B0077IM Bolt (B)

      Confirm the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration.

      Immediately after removing the service bolts and washers, install the camshaft bearing caps with the bolts in the order shown in the illustration.

      Torque:
      Bolt (A)
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt (B)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


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

      • Do not drop the service bolts or washers into the cylinder head sub-assembly LH.

    4. Check the torque of each bolt again.

  6. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B0076H9C04
      *a Paint Mark

      Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      If the paint marks are not aligned, align them by slightly turning the camshaft timing gear assembly.

  7. INSTALL CAMSHAFT


    1. B0076CCC03
      *a 5 to 10°

      Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be installed easily.

      Note

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

    2. B0072QRC05
      *a Timing Mark
      *b Mark Plate (yellow)
      *c Align

      Align the mark plate (yellow) with the timing mark of the camshaft timing gear assembly as shown in the illustration and install the No. 2 chain sub-assembly to the camshaft timing gear assembly.

    3. Clean and apply engine oil to the camshaft housing sub-assembly RH and camshaft journals.

    4. B007582C02
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    5. B0075D8C02
      *a Place chain sub-assembly onto camshaft timing gear assembly

      Install the chain sub-assembly to the camshaft, and then place the camshaft onto the camshaft housing sub-assembly RH.

      Tech Tips


      • Place the chain sub-assembly onto the camshaft timing gear assembly but do not engage the teeth of the sprocket with the chain sub-assembly.

      • Install the camshaft so that the timing mark is facing upward.

  8. INSTALL NO. 2 CAMSHAFT


    1. Clean and apply engine oil to the camshaft housing sub-assembly RH and No. 2 camshaft journals.

    2. B0076XYC04
      *a Mark Plate (yellow)
      *b Timing Mark

      Pass the No. 2 camshaft through the No. 2 chain sub-assembly from the front of the engine, align the mark plate (yellow) with the timing mark and install the No. 2 chain sub-assembly to the camshaft timing exhaust gear assembly RH.

    3. B0075VW

      While lifting the No. 2 camshaft, pass the No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and set it in place.

    4. Install the No. 2 camshaft to the camshaft housing sub-assembly RH, and then install the No. 2 chain tensioner assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  9. INSTALL CAMSHAFT BEARING CAP (for Bank 1)


    1. Clean and apply engine oil to the camshaft bearing caps.

    2. B007582C02
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem
      *4 Valve Stem Cap

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

    3. B007451C05
      *a Service Bolt and Washers (Used to temporarily secure the camshaft housing sub-assembly RH)
      *b Remove the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH
      *c Part to be installed
      B0073AQ Bolt (A)
      B0077IM Bolt (B)

      Confirm the marks and numbers on the camshaft bearing caps, and then remove the service bolts and washers in the order shown in the illustration.

      Immediately after removing the service bolts and washers, install the bearing caps with the bolts in the order shown in the illustration.

      Torque:
      Bolt (A)
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt (B)
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

      Note


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

      • Do not drop the service bolts or washers into the cylinder head sub-assembly RH.

    4. Check the torque of each bolt again.

  10. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B0076QHC05
      *a Paint Mark

      Align the paint marks on the camshaft timing gear assembly and chain sub-assembly, and install the chain sub-assembly to the camshaft timing gear assembly.

      Tech Tips

      If the paint marks are not aligned, align them by slightly turning the camshaft timing gear assembly.

  11. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0072L8C01
      *a 0°
      *b 30°

      Turn the crankshaft 30° counterclockwise past the "0" timing mark, and then turn it clockwise to align the notch with the "0" timing mark.

    2. Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly.

      Tech Tips

      Make sure there is some slack in the chain sub-assembly around the area where the No. 1 chain tensioner assembly is installed.

    3. B0077LDC18
      *a Stopper Plate
      *b Pin
      *c Push

      Turn the stopper plate of the No. 1 chain tensioner assembly clockwise, and push in the plunger of the No. 1 chain tensioner assembly as shown in the illustration.

    4. Turn the stopper plate of the No. 1 chain tensioner assembly counterclockwise, and insert a pin of 1.27 mm (0.0500 in.) diameter into the holes in the stopper plate and No. 1 chain tensioner assembly to secure the stopper plate in place.

    5. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    6. Remove the pin from the No. 1 chain tensioner assembly.

  12. INSPECT VALVE TIMING


    1. Check that each camshaft timing mark is positioned as shown in the illustration.

      B00735PC02
      *a Timing Mark *b Viewpoint

      Note


      • Check each timing mark from a viewpoint directly in line with the center of the camshaft and the timing mark on each camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      • If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.

      Tech Tips

      For Intake Camshaft:

      B0076DSN04

      Be sure to check the mark (A) at the point when the marks (B), (C) and (D) are positioned in line. If the marks are checked from any other viewpoint, they cannot be checked correctly.

    2. If the timing marks are not positioned correctly, reinstall the chain sub-assembly again.

    3. Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.

  13. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

      Torque:
      9.1 N*m  { 93 kgf*cm, 81 in.*lbf }

  14. INSTALL SPARK PLUG TUBE GASKET

    Click here

  15. POUR ENGINE OIL

    B00738A

    Tech Tips

    Before installing the cylinder head cover sub-assemblies, pour engine oil into the oil holes shown in the illustration until the oil holes are filled with engine oil.

  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head cover sub-assembly.

      Click here

    2. Attach the clamps and connect the connectors to the cylinder head cover sub-assembly.

  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


    1. Install the cylinder head cover sub-assembly LH.

      Click here

    2. Attach the clamps and connect the connectors to the cylinder head cover sub-assembly LH.

  18. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

    Click here

  19. INSTALL NO. 2 OIL PIPE

    Click here

  20. INSTALL NO. 1 OIL PIPE


    1. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install the No. 1 oil pipe to the cylinder head cover sub-assembly LH with the oil pipe union.

      Note


      • Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

      • Do not touch the mesh when installing the oil control valve filter LH.

    2. Install a new gasket and temporarily install the No. 1 oil pipe to the cylinder head sub-assembly LH with the oil check valve bolt.

    3. B00737U

      Using a 17 mm ball joint lock nut wrench, tighten the oil pipe union on the cylinder head cover sub-assembly LH side.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench

      Click here

    4. Tighten the oil check valve bolt on the cylinder head sub-assembly LH side.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

      Note

      If the link that connects the gaskets is broken, remove the connecting link by using nippers or equivalent.

  21. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  22. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  23. INSTALL SPARK PLUG

    Click here

  24. INSTALL IGNITION COIL ASSEMBLY

    Click here

  25. INSTALL INJECTOR DRIVER

    Click here

  26. INSTALL NO. 1 ENGINE COVER

    Click here

  27. INSTALL GENERATOR ASSEMBLY

    Click here

  28. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

    Click here

  29. INSTALL BATTERY (for LHD)

    Click here

  30. INSTALL BATTERY (for RHD)

    Click here