CAMSHAFT REMOVAL

PROCEDURE


  1. REMOVE RADIATOR ASSEMBLY

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  2. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  3. REMOVE VENTILATION HOSE

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  4. REMOVE NO. 4 VENTILATION HOSE

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  5. DISCONNECT NO. 3 VENTILATION HOSE


    1. B0077G0

      Slide the clip and disconnect the No. 3 ventilation hose from the cylinder head cover sub-assembly.

  6. DISCONNECT NO. 2 VENTILATION HOSE


    1. B0076TF

      Slide the clip and disconnect the No. 2 ventilation hose from the cylinder head cover sub-assembly.

  7. REMOVE IGNITION COIL ASSEMBLY

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  8. REMOVE CAMSHAFT POSITION SENSOR (for Intake Side)

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  9. REMOVE CAMSHAFT POSITION SENSOR (for Exhaust Side)

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  10. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  11. DISCONNECT ENGINE WIRE


    1. B0077BS

      Disengage the clamp and disconnect the No. 3 ventilation hose from the engine wire

    2. Disconnect the air fuel ratio sensor connector.

    3. Remove the bolt and disconnect the engine wire from the cylinder head cover sub-assembly.

  12. REMOVE NO. 1 TURBO WATER PIPE


    1. B0074GQC02
      *1 No. 1 Turbo Water By-pass Hose
      *2 No. 2 Turbo Water By-pass Hose
      *3 No. 3 Turbo Water By-pass Hose
      *4 No. 4 Turbo Water By-pass Hose
      *5 No. 1 Turbo Water Pipe

      Slide the 4 clips and disconnect the No. 1 turbo water by-pass hose, No. 2 turbo water by-pass hose, No. 3 turbo water by-pass hose and No. 4 turbo water by-pass hose.

    2. Remove the 3 bolts and No. 1 turbo water pipe.

  13. REMOVE VACUUM PUMP ASSEMBLY

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  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  15. REMOVE CYLINDER HEAD COVER GASKET

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  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B007811C01
      *a Paint Mark
      *b Timing Mark (Groove)
      *c Timing Mark "0"

      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.

    2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly is positioned as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing mark (groove) as shown in the illustration.

    3. Place paint marks on the chain sub-assembly in alignment with the timing mark (groove) on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

  17. REMOVE TIMING CHAIN COVER PLATE

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  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0074OTC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    2. B0076E9C01
      *a Approximately 15°

      Turn the crankshaft approximately 15° counterclockwise.

    3. B0077ASC01
      *a Stopper Plate
      *b Pin

      Align the holes of the stopper plate and No. 1 chain tensioner assembly, and insert a pin into the stopper plate hole to lock the No. 1 chain tensioner assembly.

    4. B0074OTC01
      *a Approximately 15°

      Turn the crankshaft approximately 15° clockwise.

    5. B0077P7

      Remove the bolt, nut, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

      Note

      Be careful not to drop the gasket into the timing chain cover assembly.

    6. B0076E9C01
      *a Approximately 15°

      Turn the crankshaft approximately 15° counterclockwise.

  19. REMOVE TIMING CHAIN GUIDE

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  20. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY

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  21. REMOVE CAMSHAFT TIMING GEAR BOLT


    1. B0074NKC01
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt from the camshaft.

      Note

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

  22. REMOVE CAMSHAFT BEARING CAP


    1. B0074C1N03

      Remove the 11 bolts in several steps in the order shown in the illustration.

    2. B0076EBC04
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 3 Camshaft Bearing Cap
      *4 No. 4 Camshaft Bearing Cap

      Remove the 10 bolts in the several steps in the order shown in the illustration.

      Note

      Make sure to loosen the bearing cap bolts evenly while holding the camshaft horizontally.

    3. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  23. REMOVE CAMSHAFT


    1. B00755F

      Raise the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.

  24. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B0076L9

      Remove the camshaft timing gear assembly.

      Note

      Do not disassemble the camshaft timing gear assembly.

  25. REMOVE NO. 2 CAMSHAFT


    1. B00780C

      Remove the No. 2 camshaft from the camshaft housing sub-assembly.

    2. B0073ND

      Suspend the chain sub-assembly with a string or equivalent as shown in the illustration.

      Note

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

  26. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Secure the No. 2 camshaft between aluminum plates in a vise.


      1. B0074K0C01
        *a Hexagonal Portion

        Using SST, grip the hexagonal portion, and then secure 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. B00780S

      Remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

      Note


      • Be careful not to damage the No. 2 camshaft and camshaft timing exhaust gear assembly.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  27. REMOVE OIL CONTROL VALVE FILTER

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  28. REMOVE NO. 1 CAMSHAFT BEARING

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  29. REMOVE NO. 2 CAMSHAFT BEARING

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  30. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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