CAMSHAFT REMOVAL


  1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

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  2. INSTALL ENGINE STAND


    1. Install the engine onto an engine stand with the bolts.

  3. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts and No. 1 and No. 2 engine hangers.

  4. REMOVE THROTTLE BODY ASSEMBLY


    1. Type A:


      1. A003WJA

        Disconnect the connector.

      2. Disconnect the No. 1 water by-pass hose and No. 2 water by-pass hose.

      3. Remove the 2 bolts, 2 nuts and throttle body assembly.

      4. A003WFN

        Remove the gasket from the intake manifold.

    2. Type B:


      1. A003VWS

        Disconnect the connector.

      2. Disconnect the No. 1 water by-pass hose and No. 2 water by-pass hose.

      3. Remove the 4 bolts and throttle body assembly.

      4. A003WGA

        Remove the gasket from the intake manifold.

  5. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Remove the engine oil level dipstick.

    2. A003ZA1

      Remove the 2 bolts, clamp and engine oil level dipstick guide.

    3. Remove the O-ring from the engine oil level dipstick guide.

  6. REMOVE EGR PIPE ASSEMBLY (w/ EGR System)


    1. A003XYD

      Disconnect the 2 wire harness clamps.

    2. A003YI1

      Remove the bolt and wire harness support.

    3. A003YX6

      Remove the 4 bolts, EGR pipe assembly and 2 gaskets.

  7. REMOVE EGR VALVE ASSEMBLY (w/ EGR System)


    1. A003WCO

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A003WD3E01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" socket wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A003ZIH

      Remove the 2 nuts, EGR valve assembly and gasket.

  8. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY (w/ EGR System)


    1. A003WCO

      Disconnect the connector, wire harness clamp and 4 water hoses.

    2. A003WD3E01
      Text in Illustration
      *1 Stud Bolt and Nut

      Remove the 4 nuts and bolt.

    3. Using an E8 "TORX" socket wrench, remove the 4 stud bolts and EGR valve with cooler assembly.

    4. Remove the gasket.

    5. A003XRK

      Remove the 2 nuts, EGR cooler sub-assembly and gasket.

  9. REMOVE WATER BY-PASS PIPE (w/o EGR System)


    1. A003YBG

      Disconnect the 2 water by-pass hoses.

    2. Remove the 2 bolts, nut and water by-pass pipe.

  10. REMOVE INTAKE MANIFOLD


    1. w/o EGR System:


      1. A003WJV

        Disconnect the 2 wire harness clamps from the wire harness support.

      2. A003WQ0

        Remove the bolt and wire harness support from the surge tank cover.

      3. A003ZUX

        Remove the 2 bolts and surge tank cover from the intake manifold.

      4. Remove the gasket from the intake manifold.

    2. A003ZLL

      Disconnect the 3 connectors and 2 wire harness clamps.

    3. Remove the engine oil level dipstick.

    4. A003XWA

      Disconnect the wire harness clamp, and then remove the 2 bolts and engine oil level dipstick guide sub-assembly.

    5. Remove the O-ring from the engine oil level dipstick guide sub-assembly.

    6. A003VBE

      Disconnect the fuel vapor feed hose and ventilation hose from the intake manifold.

    7. A003VFZ

      Remove the 2 bolts, 2 nuts and intake manifold.

    8. Remove the No. 1 intake manifold to head gasket from the intake manifold.

    9. w/ Stud Bolt:


      1. A003Y6A

        Using an E6 "TORX" socket wrench, remove the 2 stud bolts from the intake manifold.

        Tech Tips

        If a stud bolt is deformed or the threads are damaged, replace the stud bolt.

  11. REMOVE FUEL VAPOR FEED PIPE


    1. A003W3O

      Remove the bolt and fuel vapor feed pipe.

  12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A003VP4

      Remove the bolt.

    2. A003Z7A

      Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

  13. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A003VR5

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

  14. REMOVE FUEL INJECTOR ASSEMBLY


    1. A003WXD

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

    2. Remove the O-ring from each fuel injector assembly.

    3. For reinstallation, attach a tag or label with the corresponding cylinder number to each fuel injector shaft.

      Note

      Protect the fuel injector assemblies by covering them with plastic bags.

    4. A003YPM

      Remove the 4 injector vibration insulators.

  15. REMOVE IGNITION COIL ASSEMBLY


    1. A003VYT

      Disconnect the 4 ignition coil connectors.

    2. Remove the 4 bolts and 4 ignition coils.

      Note

      When removing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.

  16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A003VEM

      Remove the 13 bolts, seal washer and cylinder head cover.

      Note

      As the gaskets may stick to the cylinder head cover, be careful not to drop any of the gaskets into the engine when removing the cylinder head cover.

    2. A003XE0

      Remove the 2 gaskets from the camshaft bearing cap.

  17. REMOVE CYLINDER HEAD COVER GASKET


    1. A003V1Q

      Remove the cylinder head cover gasket.

  18. REMOVE SPARK PLUG TUBE GASKET


    1. A003Y52

      Pry up the 4 claws of the ventilation baffle plate.

      Note

      Do not deform the claws of the baffle plate more than necessary.

    2. Remove the 4 gaskets from the cylinder head cover.

      Tech Tips

      Prevent the plug tube gaskets from being deformed as much as possible. The removed gaskets will be used when installing new gaskets.

      Note

      Be careful not to damage the cylinder head cover.

  19. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A003W15E01
      Text in Illustration
      *1 Timing Mark
      *2 Timing Notch
      *3 Timing Mark (Rectangle)
      *4 Mark (Circle)

      Turn the crankshaft pulley until its notch and timing mark "0" of the timing chain cover are aligned.

      Tech Tips

      There are 3 marks on the camshaft timing sprocket. Make sure that the timing mark (rectangle) is at the top.

    2. Check that the timing marks on both the camshaft timing sprocket and the camshaft timing gear are facing upward as shown in the illustration.

      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

  20. REMOVE CRANKSHAFT PULLEY


    1. A003VJEE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, hold the pulley in place and loosen the pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A003VCUE02
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, remove the crankshaft pulley and pulley bolt.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  21. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A003YAP

      Remove the 2 nuts, bracket, chain tensioner and gasket.

      Note

      Do not turn the crankshaft without the No. 1 chain tensioner installed.

  22. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A003WBY

      Remove the 3 bolts and engine mounting bracket RH.

    2. A003W66

      Remove the 4 bolts and oil filter bracket.

    3. A003V4O

      Remove the 2 O-rings.

    4. A003Y3KE01
      Text in Illustration
      *1 Seal Washer

      Remove the 18 bolts and seal washer.

    5. A003VM6E01
      Text in Illustration
      *1 Protective Tape

      Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

      Note


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

      • Pry the timing chain cover out evenly in order to prevent damaging the knock pins.

      Tech Tips

      Tape the screwdriver tip before use.

    6. A003XNX

      Remove the 3 O-rings.

  23. REMOVE TIMING CHAIN COVER OIL SEAL


    1. Place the timing chain cover on wooden blocks.

    2. A003YXEE01
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Using a screwdriver and hammer, knock out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  24. REMOVE CHAIN TENSIONER SLIPPER


    1. A003Z3Q

      Remove the chain tensioner slipper from the cylinder block.

  25. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A003WFM

      Remove the 2 bolts and chain vibration damper.

  26. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A003Y2U

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

  27. REMOVE CHAIN SUB-ASSEMBLY


    1. A003WCW

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear counterclockwise to loosen the chain between the camshaft timing gears.

    2. With the chain loosened, release the chain from the camshaft timing gear and place it on the camshaft timing gear.

      Tech Tips

      Be sure to release the chain from the sprocket completely.

    3. Turn the camshaft clockwise to return it to the original position and remove the chain.

  28. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Inspect the lock of the camshaft timing gear.

    2. A003VAFE02
      Text in Illustration
      *1 Adhesive Tape
      *a Adhesive Tape Sealing Area
      *b Prick a Hole

      After cleaning and degreasing 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 cover 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. A003YZA

      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 the 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 in the advance direction (counterclockwise).

      Tech Tips

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

    6. A003ZVZ

      Turn the camshaft timing gear 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 turns smoothly.

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

  29. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A003VJ4
      Text in Illustration
      *1 Flange Bolt
      *a Do not remove

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

      Note


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

      • A003W2TE04

        Be sure not to remove the other 4 bolts.

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

  30. REMOVE CAMSHAFT TIMING SPROCKET


    1. A003YKW

      Remove the flange bolt while holding the hexagonal portion of the camshaft with a wrench, and then remove the camshaft timing sprocket.

  31. REMOVE CAMSHAFT BEARING CAP


    1. A003YDLE01

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

    2. A003XNZE01

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

      Note

      Uniformly loosen the bearing cap bolts while keeping the camshaft housing level.

    3. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  32. REMOVE CAMSHAFT


    1. A003ZLS

      Remove the camshaft.

  33. REMOVE NO. 2 CAMSHAFT


    1. A003VQU

      Remove the No. 2 camshaft.

  34. REMOVE NO. 1 CAMSHAFT BEARING


    1. A003W9X

      Remove the 2 No. 1 camshaft bearings.

  35. REMOVE NO. 2 CAMSHAFT BEARING


    1. A003WJZ

      Remove the 2 No. 2 camshaft bearings.

  36. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A003YKX

      Remove the 2 bolts.

    2. A003XFLE02
      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.