CAMSHAFT REMOVAL

PROCEDURE


  1. DRAIN ENGINE COOLANT

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  2. PRECAUTION

    Note

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work.

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  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE BATTERY

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  5. REMOVE NO. 1 BATTERY TRAY SUPPORT

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  6. REMOVE FUEL PUMP ASSEMBLY (for High Pressure)

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  7. SEPARATE WIRE HARNESS


    1. Remove the bolt, 4 nuts, 5 clamps and 2 connectors and separate the wire harness.

      B0074K5C02
      B0073AQ Bolt B0077IM Nut
      B0077LI connector - -

  8. DISCONNECT INLET HEATER WATER HOSE A

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  9. DISCONNECT OUTLET HEATER WATER HOSE A

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  10. REMOVE NO. 2 WATER BY-PASS PIPE

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  11. DISCONNECT UNION TO CONNECTOR TUBE HOSE (for RHD)

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  12. REMOVE VACUUM PUMP ASSEMBLY

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  13. REMOVE WIRE HARNESS CLAMP BRACKET


    1. B0075DR

      Disengage the wire harness clamp from the wire harness clamp bracket.

    2. Remove the 2 bolts and the wire harness clamp bracket from cylinder head cover sub-assembly LH.

    3. B0073UV

      Remove the bolt and the wire harness clamp bracket from the cylinder head cover sub-assembly LH.

  14. REMOVE NO. 1 RADIATOR HOSE

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  15. REMOVE NO. 2 RADIATOR HOSE SUB-ASSEMBLY

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  16. REMOVE WATER OUTLET SUB-ASSEMBLY

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  17. REMOVE NO. 1 WATER BY-PASS PIPE (w/ Oil Cooler)

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  18. REMOVE IGNITION COIL ASSEMBLY

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  19. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

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  20. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)

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  21. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)

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  22. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)

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  23. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)

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  24. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY

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  25. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

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  26. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  27. REMOVE SPARK PLUG TUBE GASKET

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  28. REMOVE TIMING CHAIN COVER PLATE


    1. B0074C7

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

  29. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B0075LWC07
      *a "0" Timing Mark
      *b Timing Mark (cutout)

      Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.

    2. B00760DC04
      *A for Bank 2
      *B for Bank 1
      *a Paint Mark (yellow)
      *b Timing Mark

      Check that the timing marks of the camshaft timing gear assemblies are aligned with the timing marks of the camshaft 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 assembly and on the links of the chain sub-assembly.

      Tech Tips

      Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gear assemblies at the locations of the timing marks of the camshaft timing gear assemblies.

  30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0073JVC03
      *a 30°

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

      Tech Tips

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

    2. B0077MIC15
      *a Lever Hole
      *b Tensioner Hole

      Align the hole in the lever of the No. 1 chain tensioner assembly with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole.

      Note

      Check that the pin is locked.

    3. B0075LWC07
      *a "0" Timing Mark
      *b Timing Mark (cutout)

      Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.

    4. B0076SQ

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

      Note

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

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


    1. B0073JTC03
      *a 30°

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

      CAUTION:

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

      Tech Tips

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

    2. B0076CCC07
      *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 removed easily.

      Tech Tips

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

    3. B0073TI

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

      CAUTION:

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

  32. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B0073WF

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

  33. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)


    1. B0074WSC04
      *a Hold
      B0073AQ Turn

      Use a wrench to hold the hexagonal portion of the camshaft and remove the camshaft timing gear bolt from the camshaft timing gear assembly.

      Note

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

  34. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)


    1. B0077S7C05
      *a Hold
      B0073AQ Turn

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly RH.

      Note

      Be careful not to damage the No. 2 camshaft or camshaft housing sub-assembly with the wrench.

  35. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B0077QB

      Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly RH as shown in the illustration.

    2. B007567C02
      *a Replacement Bolt and Washer
      *b Part Removal
      *c Replacement Bolt and Washer Installation

      Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

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

      Note


      • Do not install the camshaft bearing caps when installing replacement bolts and washers.

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

      • Do not allow replacement bolts or washers to contact the camshaft.

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

      Tech Tips


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

      • Part number for replacement bolts: 91551-F0850 (9 bolts)

      • Part number for replacement washers: 90201-12028 (18 washers)

  36. REMOVE NO. 2 CAMSHAFT


    1. B0077M1

      While lifting up the camshaft timing exhaust gear assembly RH, remove the No. 2 chain tensioner assembly.

    2. Lift up the rear of the No. 2 camshaft so that it is at an angle.

    3. B0073XL

      Pull the No. 2 camshaft as shown in the illustration to remove it from the camshaft timing exhaust gear assembly RH.

  37. REMOVE CAMSHAFT


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

    2. B0074A0

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

  38. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH (for Bank 1)


    1. B007480

      Remove the camshaft timing exhaust gear assembly RH.

  39. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1)


    1. B0072WZ

      Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.

      Note

      Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

    2. B00757Q

      Suspend the chain sub-assembly with a string or equivalent.

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


    1. B0075LWC06
      *a "0" Timing Mark
      *b Timing Mark (cutout)

      Turn the crankshaft counterclockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.

    2. B0073MT

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

      CAUTION:

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

  41. DISCONNECT NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B0075N1

      Remove the bolt to separate the No. 3 chain tensioner assembly from the camshaft housing sub-assembly LH.

  42. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)


    1. B00744JC04
      *a Hold
      B0073AQ Turn

      Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly and remove the camshaft timing gear bolt from the camshaft timing gear assembly.

      Note

      Be careful not to damage the No. 3 camshaft sub-assembly or cylinder head LH with the wrench.

  43. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)


    1. B0074MYC04
      *a Hold
      B0073AQ Turn

      Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly LH.

      Note

      Be careful not to damage the No. 4 camshaft sub-assembly or cylinder head LH with the wrench.

  44. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B0076CE

      Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly LH as shown in the illustration.

    2. B00750NC02
      *a Replacement Bolt and Washer
      *b Part Removal
      *c Replacement Bolt and Washer Installation

      Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

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

      Note


      • Do not install the camshaft bearing caps when installing replacement bolts and washers.

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

      • Do not allow replacement bolts or washers to contact the camshaft.

      • Do not drop replacement bolts or washers into the cylinder head LH.

      Tech Tips


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

      • Part number for replacement bolts: 91551-F0850 (8 bolts)

      • Part number for replacement washers: 90201-12028 (16 washers)

  45. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. B0076BM

      While lifting up the camshaft timing exhaust gear assembly LH, remove the No. 3 chain tensioner assembly.

    2. Lift up the rear of the No. 4 camshaft sub-assembly so that it is at an angle.

    3. B0074QQ

      Pull the No. 4 camshaft sub-assembly toward the rear of the vehicle to remove it from the camshaft timing exhaust gear assembly LH.

  46. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Lift up the rear of the No. 3 camshaft sub-assembly so that it is at an angle.

    2. B0075A6

      Pull the No. 3 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing gear assembly.

  47. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH (for Bank 2)


    1. B00775M

      Remove the camshaft timing exhaust gear assembly LH.

  48. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2)


    1. B0074CN

      Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.

      Note

      Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

    2. B0075X1

      Suspend the chain sub-assembly with a string or equivalent.