CAMSHAFT REMOVAL

PROCEDURE


  1. REMOVE ENGINE UNDER COVER RH

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  2. REMOVE NO. 1 IGNITION COIL

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  3. DISCONNECT VENTILATION HOSE

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  4. DISCONNECT NO. 2 VENTILATION HOSE

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  5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  6. REMOVE FAN AND GENERATOR V BELT

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  7. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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  8. REMOVE NO. 2 CAMSHAFT

    A005KCGE03
    Text in Illustration
    *a Alignment Mark

    Note

    When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40 ° from the TDC and align the timing notch with the alignment mark of the timing chain cover to prevent the pistons from coming into contact with the valves.


    1. Set the No. 1 cylinder to TDC/compression.


      1. A005HWTE20
        Text in Illustration
        *a Timing Notch

        Turn the crankshaft damper, and align the timing notch with the timing mark "0" of the oil pump.

      2. A005HQ5E17
        Text in Illustration
        *a Timing Mark

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

        Tech Tips

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

    2. A005MHHE11
      Text in Illustration
      *a Paint Mark
      *b Timing Mark

      Place paint marks on the chain where it touches the timing marks on the camshaft timing sprocket and the camshaft timing gear.

    3. A005HY2

      Using an 8 mm (0.31in.) hexagon wrench, remove the screw plug.

    4. A005LMZE02
      Text in Illustration
      *1 Stopper Plate

      Insert a screwdriver into the service hole in the chain tensioner to pull the stopper plate of the chain tensioner upward.

    5. A005KIX
      Text in Illustration
      *1 Plunger

      Using a wrench, rotate the No. 2 camshaft clockwise to push in the plunger of the chain tensioner.

    6. A005GD3

      Remove the screwdriver from the service hole, then align the hole the stopper plate with the service hole and insert a 3 mm (0.12 in.) diameter bar into the holes to hold the stopper plate.

      Tech Tips


      • Fix the stopper plate using the bar while rotating the camshaft right and left slightly.

      • Hold the bar with tape so that the bar does not come off.

    7. A005IAJ

      Using a wrench, hold the hexagonal lobe of the No. 2 camshaft and remove the flange bolt.

    8. A005L13E01

      Using several steps, loosen and remove the 11 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 1 and No. 2 camshaft bearing caps.

      Note

      Loosen the bolts uniformly while keeping the camshaft level.

    9. A005K9Q

      Remove the flange bolt and remove the camshaft timing sprocket.

    10. A005J7M

      Remove the No. 2 camshaft.

  9. REMOVE CAMSHAFT


    1. A005H35E02

      Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the No. 2 camshaft bearing cap.

      Note

      Loosen each bolt uniformly while keeping the camshaft level.

    2. A005MDA

      Hold the chain by hand, and remove the camshaft and the camshaft timing gear assembly.

    3. A005GNH

      Tie the chain with a piece of string as shown in the illustration.

  10. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. Clamp the camshaft in a vise and confirm that it is locked.

      Note

      Do not damage the camshaft.

    2. A005M2ZE19
      Text in Illustration
      *1 Rubber Piece
      *2 Vinyl Tape
      *a Advance Side Path
      *b Retard Side Path
      *c Open
      *d Close

      Cover the 4 oil paths of the cam journal with tape as shown in the illustration.

      Tech Tips

      One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with the tape.

    3. Puncture the tape covering the advance oil path and the retard oil path on the opposite side from the advance oil path.

    4. A005M6FE04
      Text in Illustration
      *a Advance Side Path
      *b Retard Side Path

      Apply air at about 150 kPa (1.5 kgf*cm2) pressure into the 2 broken paths (the advance side path and the retard side path).

      Note

      Cover the paths with a piece of cloth to prevent oil splashes.

    5. A005KUJE04
      Text in Illustration
      *a Advance Side Path
      *b Retard Side Path
      *c Hold Pressure
      *d Decompress

      Confirm that the camshaft timing gear assembly revolves in the timing advance direction when the air pressure on the timing retard path is reduced.

      Tech Tips

      The lock pin is released, and the camshaft timing gear revolves in the advance direction.

    6. When the camshaft timing gear reaches the most advanced position, release the air pressure on the timing retard side path, and then release the air pressure on the timing advance side path.

      Note

      The camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air pressure on the advance side path is released first. This often results in the breakage of the lock pin.

    7. A005GIY

      Remove the flange bolt and remove the camshaft timing gear assembly.

      Note


      • Do not remove the other 4 bolts.

      • When reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.