CAMSHAFT REMOVAL

PROCEDURE


  1. INSTALL ENGINE ON ENGINE STAND

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  2. REMOVE ENGINE HANGER

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  3. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY

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  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  6. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  7. REMOVE MANIFOLD STAY

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  8. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  9. REMOVE FUEL DELIVERY PIPE

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  10. REMOVE FUEL INJECTOR ASSEMBLY

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  11. REMOVE NO. 1 DELIVERY PIPE SPACER

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  12. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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  13. REMOVE EGR PIPE CONNECTOR

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  14. REMOVE INTAKE MANIFOLD

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  15. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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  16. REMOVE EGR VALVE ASSEMBLY

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  17. REMOVE IGNITION COIL ASSEMBLY

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  18. REMOVE VENTILATION HOSE

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  19. REMOVE NO. 2 VENTILATION HOSE

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  20. REMOVE NO. 1 WATER BY-PASS PIPE

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  21. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  22. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR

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  23. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  24. REMOVE WATER INLET

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  25. REMOVE NO. 2 WATER INLET HOUSING GASKET

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  26. REMOVE CRANKSHAFT POSITION SENSOR

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  27. REMOVE CRANKSHAFT PULLEY

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  28. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  29. REMOVE TIMING CHAIN COVER OIL SEAL

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  30. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  31. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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  32. REMOVE TIMING CHAIN TENSION ARM

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  33. REMOVE CHAIN SUB-ASSEMBLY

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  34. REMOVE TIMING CHAIN GUIDE

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  35. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Inspect the lock of the camshaft timing gear.

    2. A005M84E06
      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 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. A005KN8

      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. A005I8E

      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.

  36. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


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

    2. A005ILBE05
      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 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. A005HLG

      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. A005JRA

      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.

  37. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A005IUUE06
      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.

  38. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A005IKOE05
      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.

  39. REMOVE CAMSHAFT BEARING CAP


    1. A005M29E02

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

    2. A005MBRE02

      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.

  40. REMOVE NO. 2 CAMSHAFT


    1. A005KN0

      Remove the No. 2 camshaft.

  41. REMOVE CAMSHAFT


    1. A005KD4

      Remove the camshaft.

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

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  43. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A005H00

      Remove the 3 bolts.

    2. A005LEJE02
      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.

  45. INSPECT CAMSHAFT

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  46. INSPECT NO. 2 CAMSHAFT

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  47. INSPECT CAMSHAFT THRUST CLEARANCE

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  48. INSPECT CAMSHAFT OIL CLEARANCE

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

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  50. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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