CAMSHAFT REMOVAL


  1. INSTALL ENGINE STAND

    Click here

  2. REMOVE ENGINE HANGER


    1. Remove the 2 bolts and 2 engine hangers.

  3. REMOVE GENERATOR ASSEMBLY

    A011BS7

    1. Remove the 2 bolts and the generator.

  4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A011ARD

    1. Remove the bolt, 2 nuts and the No. 1 exhaust manifold heat insulator.

  5. REMOVE MANIFOLD STAY

    A011A6U

    1. Remove the bolt, nut and the manifold stay.

  6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    A011B97

    1. Remove the 3 bolts, 4 nuts and the exhaust manifold converter.

    2. Remove the exhaust manifold to head gasket and inlet EGR gasket from the cylinder head.

  7. DISCONNECT VENTILATION HOSE

    A0119EI

    1. Loosen the clip and disconnect the ventilation hose from the intake manifold.

  8. DISCONNECT NO. 2 WATER BY-PASS HOSE

    A011AUX

    1. Loosen the clip and disconnect the No. 2 water by-pass hose from the throttle body.

  9. DISCONNECT NO. 4 WATER BY-PASS HOSE

    A011BMB

    1. Loosen the clip and disconnect the No. 4 water by-pass hose from the EGR valve.

  10. REMOVE INTAKE MANIFOLD STAY

    A0117HL

    1. Remove the 2 bolts and the intake manifold stay.

  11. REMOVE EGR PIPE CONNECTOR

    A0118NG

    1. Remove the 4 nuts and the EGR pipe connector.

    2. Remove the 2 EGR pipe gaskets from the intake manifold and EGR valve.

  12. REMOVE INTAKE MANIFOLD ASSEMBLY

    A011BRY

    1. Remove the 5 bolts, 2 nuts and the intake manifold.

    2. A011A93

      Remove the intake manifold to head gasket from the cylinder head.

    3. A0117Z0

      Remove the EGR delivery chamber from the cylinder head.

    4. A0117ZA

      Remove the No. 2 intake manifold to head gasket from the cylinder head.

  13. REMOVE NO. 4 ENGINE WIRE

    A011BC9

    1. Disconnect the 2 camshaft timing oil control valve connectors.

    2. Disconnect the 4 ignition coil connectors.

    3. Disconnect the 4 fuel injector connectors.

    4. Remove the ground bolt.

    5. Disengage the 7 clamps and remove the No. 4 engine wire.

  14. REMOVE ENGINE OIL LEVEL DIPSTICK

  15. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

    A011708

    1. Remove the 2 bolts and the engine oil level dipstick guide.

    2. Remove the O-ring from the oil level dipstick guide.

  16. REMOVE EGR VALVE ASSEMBLY

    A011877

    1. Remove the bolt, 2 nuts and the EGR valve.

    2. Remove the EGR valve gaskets.

  17. REMOVE FUEL DELIVERY PIPE


    1. A011BP1

      Disconnect the 4 fuel injector assembly connectors.

    2. A011889

      Remove the 2 bolts and delivery pipe together with the 4 injectors.

      Note

      Do not drop the fuel injectors when removing the fuel delivery pipe.

  18. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01175T

      Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

    2. A011740

      For reinstallation, attach a tag or label to each injector shaft.

      Note

      Prevent entry of foreign objects by covering the fuel injectors with plastic bags.

  19. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A0117T9

      Remove the 2 No. 1 delivery pipe spacers from the cylinder head.

  20. REMOVE INJECTOR VIBRATION INSULATOR


    1. A0117ZB

      Remove the 4 injector vibration insulators.

  21. REMOVE NO. 1 IGNITION COIL


    1. Remove the 4 bolts and remove the 4 No. 1 ignition coils.

  22. REMOVE VENTILATION HOSE

    A0119L3

    1. Remove the ventilation hose from the cylinder head cover.

  23. REMOVE NO. 2 VENTILATION HOSE

    A011855

    1. Remove the No. 2 ventilation hose from the cylinder head cover.

  24. REMOVE NO. 1 WATER BY-PASS PIPE

    A011A05E01
    Text in Illustration
    *1 No. 2 Water By-Pass Hose
    *2 No. 1 Water By-Pass Pipe
    *3 Water By-Pass Hose

    1. Disengage the No. 2 water by-pass hose from the 3 clamps.

    2. Remove the 3 bolts.

    3. Disconnect the water by-pass hose and remove the No. 1 water by-pass pipe.

  25. REMOVE NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)

    A0119MW

    1. Remove the 4 bolts and the No. 2 idle pulley assembly with bracket.

  26. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

    A011A92

    1. Remove the 2 bolts and the V-ribbed belt tensioner.

  27. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (w/ No. 1 Engine Cover)

    A011A9N

    1. Remove the 2 bolts, V-ribbed belt tensioner and engine cover bracket.

  28. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR

    A011A0K

    1. Remove the 2 bolts and the 2 No. 1 crankshaft position sensors.

  29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

    A0119V3E01
    Text in Illustration
    *1 Seal Washer

    1. Remove the 18 bolts, 2 seal washers and the cylinder head cover.

      Note

      Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.

    2. A01186E

      Remove the cylinder head cover gasket.

  30. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET


    1. A011ASE

      Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.

  31. REMOVE CRANKSHAFT POSITION SENSOR

    A011BVM

    1. Remove the bolt and the crankshaft position sensor.

  32. REMOVE WATER PUMP PULLEY

    A011BEJE01

    1. Using SST, remove the 4 bolts and water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00600 )

  33. REMOVE CRANKSHAFT PULLEY

    A01170JE01

    1. Using SST, remove the crankshaft pulley bolt.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Remove the crankshaft pulley from the crankshaft.

  34. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    A011A38

    1. Remove the 5 bolts and the water pump, water pump gasket from the timing chain cover.

    2. A0117GS

      Remove the 3 bolts and the engine mounting bracket.

    3. A011BK7E01
      Text in Illustration
      *1 Seal Washer

      Remove the 21 bolts and seal washer.

    4. A011AS0E01
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block.

      Note

      Be careful not to damage the contact surfaces of the timing chain cover, cylinder block, and cylinder head.

    5. A01194Z

      Remove the 2 O-rings.

    6. A0118R7

      Using an 8 mm socket hexagon wrench, remove the plug.

  35. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01195KE03
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.

      Note

      Do not damage the surface of the oil seal press fit hole.

  36. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    A0117MZE01

    1. Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.

      Text in Illustration
      *1 Timing Mark
      *a TDC
    2. A0119YJE03
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger
      A0117XZ Push

      Push down on the stopper plate to release the lock and push in the plunger.

    3. A011B2ZE02
      Text in Illustration
      *1 Stopper Plate

      Pull up the stopper plate with the plunger pushed to the end and lock the plunger.

    4. A01188UE02
      Text in Illustration
      *1 Bar

      Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.

    5. A01189X

      Remove the 2 nuts and the No. 1 chain tensioner.

    6. A01187M

      Remove the gasket from the cylinder head.

  37. REMOVE NO. 2 CHAIN VIBRATION DAMPER

    A011A28

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

  38. REMOVE TIMING CHAIN TENSION ARM

    A011BU1

    1. Remove the bolt and the timing chain tension arm.

  39. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain.

  40. REMOVE TIMING CHAIN GUIDE

    A011741

    1. Remove the 2 bolts and the timing chain guide.

  41. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Inspect the lock of the camshaft timing gear.

    2. A011BCLE03
      Text in Illustration
      *1 Prick a Hole
      *2 Adhesive Tape
      *a Adhesive Tape Sealing Area

      After cleaning and degrease the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

      Note

      Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

    3. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure A).

    4. A0119VI

      Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

      Note


      • If air leaks out, reattach adhesive tape.

      • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

    5. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

      Tech Tips

      Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.

    6. A01173P

      Turn the camshaft timing gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

    7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

  42. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Check the lock of the camshaft timing exhaust gear.

    2. A0117O1E03
      Text in Illustration
      *1 Prick a Hole
      *2 Adhesive Tape
      *a Adhesive Tape Sealing Area

      After cleaning and degrease the VVT oil hole on the exhaust side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.

      Note

      Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

    3. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure B).

    4. A0117BS

      Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the hole pricked in procedure B to release the lock pin.

      Note


      • If air leaks out, reattach adhesive tape.

      • Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

    5. Using a screwdriver with its tip wrapped with tape, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).

      Note


      • Be sure to keep the camshaft timing exhaust gear in the retard direction using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to force from the spring.

      • Do not damage the camshaft timing exhaust gear.

    6. A01199G

      Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear within its movable range (19 to 21°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear turns smoothly.

    7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

  43. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01192QE03
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.

      Note


      • Before removing the camshaft timing gear, make sure that the lock pin has been released.

      • Be sure not to remove the other 4 bolts.

      • Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.

  44. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A011BEME02
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.

  45. REMOVE CAMSHAFT BEARING CAP


    1. A011BCJE01

      Uniformly loosen and remove the 5 bearing cap bolts in the sequence shown in the illustration.

    2. A01176CE01

      Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  46. REMOVE NO. 2 CAMSHAFT


    1. A0118XE

      Remove the No. 2 camshaft.

  47. REMOVE CAMSHAFT


    1. A011709

      Remove the camshaft.

  48. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    A0118J2

    1. Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  49. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    A011AFY

    1. Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  50. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A0117DH

      Remove the 3 bolts.

    2. A011A0EE02
      Text in Illustration
      *1 Protective Tape

      Using a screwdriver with its tip wrapped with protective tape, remove the camshaft housing by prying between the cylinder head and camshaft housing.

      Note

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

  51. INSPECT CAMSHAFT


    1. A0118N7

      Inspect the camshaft for runout.


      1. Place the camshaft on V-blocks.

      2. Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.04 mm (0.00157 in.)

        If the circle runout is greater than the maximum, replace the camshaft.

    2. A011BVH

      Inspect the cam lobes.


      1. Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        41.699 to 41.7989 mm (1.6417 to 1.6456 in.)
        Minimum cam lobe height
        41.549 mm (1.6358 in.)

        If the cam lobe height is less than the minimum, replace the camshaft.

    3. A011BDP

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Journal Position Specified Condition
        No. 1 34.454 to 34.470 mm (1.3565 to 1.3571 in.)
        Other 22.954 to 22.970 mm (0.9037 to 0.9043 in.)

        If the journal diameter is not as specified, check the camshaft oil clearance.

  52. INSPECT NO. 2 CAMSHAFT


    1. A0118N7

      Inspect the No. 2 camshaft for runout.


      1. Place the No. 2 camshaft on V-blocks.

      2. Using a dial indicator, measure the circle runout at the center journal.

        Maximum circle runout
        0.04 mm (0.00157 in.)

        If the circle runout is greater than the maximum, replace the No. 2 camshaft.

    2. A011BVH

      Inspect the cam lobes.


      1. Using a micrometer, measure the cam lobe height.

        Standard cam lobe height
        41.000 to 41.100 mm (1.6142 to 1.6181 in.)
        Minimum cam lobe height
        40.85 mm (1.6083 in.)

        If the cam lobe height is less than the minimum, replace the No. 2 camshaft.

    3. A011BDP

      Inspect the camshaft journals.


      1. Using a micrometer, measure the journal diameter.

        Standard Journal Diameter
        Journal Position Specified Condition
        No. 1 34.454 to 34.470 mm (1.3565 to 1.3571 in.)
        Other 22.954 to 22.970 mm (0.9037 to 0.9043 in.)

        If the journal diameter is not as specified, check the camshaft oil clearance.

  53. INSPECT CAMSHAFT THRUST CLEARANCE


    1. Install the camshaft Click here.

    2. A0118FX

      Install the No. 2 camshaft Click here.

    3. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

      Standard Thrust Clearance
      Item Specified Condition
      Intake 0.06 to 0.2 mm (0.00236 to 0.00787 in.)
      Exhaust 0.06 to 0.2 mm (0.00236 to 0.00787 in.)
      Maximum Thrust Clearance
      Item Specified Condition
      Intake 0.215 mm (0.00846 in.)
      Exhaust 0.215 mm (0.00846 in.)

      If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.

  54. INSPECT CAMSHAFT OIL CLEARANCE


    1. A0118UXE02
      Text in Illustration
      *1 Plastigage

      Clean the bearing caps and camshaft journals.

    2. Place the camshafts on the camshaft housing.

    3. Lay a strip of Plastigage across each of the camshaft journals.

    4. Install the camshaft bearing cap Click here.

      Note

      Do not turn the camshaft.

    5. Remove the camshaft bearing cap Click here.

    6. A011BLLE02
      Text in Illustration
      *1 Plastigage

      Measure the Plastigage at its widest point.

      Standard Oil Clearance
      Item Specified Condition
      No. 1 camshaft journal 0.030 to 0.067 mm (0.00118 to 0.00264 in.)
      Other camshaft journals 0.030 to 0.067 mm (0.00118 to 0.00264 in.)
      Maximum Oil Clearance
      Item Specified Condition
      No. 1 camshaft journal 0.08 mm (0.00315 in.)
      Other camshaft journals 0.08 mm (0.00315 in.)

      Note

      Completely remove the Plastigage after the inspection.

      If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.

  55. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A0119KG

      Turn the roller by hand to check that it turns smoothly.

      Tech Tips

      If the roller does not turn smoothly, replace the valve rocker arm.

  56. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    A0117TEE12
    Text in Illustration
    *1 Plunger
    *2 Check Ball
    *3 Low Pressure Chamber
    *4 High Pressure Chamber
    *a Correct
    *b Incorrect
    *c Taper Part

    Note


    • Keep the lash adjuster free of dirt and foreign matter.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container filled with engine oil.

    2. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed it.

      OK
      Plunger moves up and down.

      Note

      When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.

    5. After bleeding, remove SST. Then, try to quickly and firmly press the plunger by hand.

      OK
      Plunger is very difficult to move.

      If the result is not as specified, replace the lash adjuster.