CAMSHAFT INSTALLATION

PROCEDURE

1. INSTALL CAMSHAFT LH (for Bank 2)

   
   

   1. Apply engine oil to the journals of the camshaft housing sub-assembly LH.

   2. 

      Set the intake camshaft LH and the exhaust camshaft LH to the camshaft housing sub-assembly LH.

2. INSTALL CAMSHAFT CAP (for Bank 2)

   
   

   1. Using a sealer gun, apply seal packing to the contact surface of the front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent

      

      Text in Illustration

      *1	Intake Rear Camshaft Cap LH	*2	Exhaust Rear Camshaft Cap LH
      *3	Front Camshaft Cap LH	-	-
      *a	Within 1.0 mm (0.0394 in.)	*b	φ3.0 to 4.0 mm (0.1181 to 0.1575 in.)
      *c	φ2.5 to 3.5 mm (0.0984 to 0.1378 in.)	*d	φ2.5 to 4.0 mm (0.0984 to 0.1575 in.)
      *e	φ1.5 to 2.5 mm (0.0591 to 0.0984 in.)	*f	Chamfer edge

      Note

      
      

      • Clean and degrease the contact surface.

      • Do not apply excessively seal packing as it may cause excess seal packing to flow toward the cam journal, resulting in engine seizure.

      • Do not apply seal packing to the intake center camshaft cap LH and exhaust center camshaft cap LH.

      • Install the camshaft caps within 5 minutes of applying the seal packing.

   2. Apply engine oil to the journals of the camshaft caps, and place them on the camshaft housing sub-assembly LH.

   3. 

      Tighten the 13 bolts in the order shown in the illustration to install the front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH.

      Torque:

      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

3. INSTALL CAMSHAFT RH (for Bank 1)

   
   

   1. Apply engine oil to the journals of the camshaft housing sub-assembly RH.

   2. 

      Set the intake camshaft RH and the exhaust camshaft RH to the camshaft housing sub-assembly RH.

4. INSTALL CAMSHAFT CAP (for Bank 1)

   
   

   1. Using a sealer gun, apply seal packing to the contact surface of the front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH as shown in the illustration.

      Seal packing
      Three Bond 1217G, 1217H or equivalent

      

      Text in Illustration

      *1	Front Camshaft Cap RH	*2	Intake Rear Camshaft Cap RH
      *3	Exhaust Rear Camshaft Cap RH	-	-
      a	φ2.5 to 4.0 mm (0.0984 to 0.1575 in.)	b	Within 1.0 mm (0.0394 in.)
      c	φ3.0 to 4.0 mm (0.1181 to 0.1575 in.)	d	φ1.5 to 2.5 mm (0.0591 to 0.0984 in.)
      e	Chamfer edge	-	-

      Note

      
      

      • Clean and degrease the contact surface.

      • Do not apply excessively seal packing as it may cause excess seal packing to flow toward the cam journal, resulting in engine seizure.

      • Do not apply seal packing to the intake center camshaft cap RH and exhaust center camshaft cap RH.

      • Install the camshaft caps within 5 minutes of applying the seal packing.

   2. Apply engine oil to the journals of the camshaft caps, and place them on the camshaft housing sub-assembly RH.

   3. 

      Tighten the 12 bolts in the order shown in the illustration to install the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH.

      Torque:

      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

5. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

   Click here

6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

   Click here

7. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

   Click here

8. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

   Click here

9. INSTALL INJECTOR DRIVER BRACKET

   Click here

10. INSTALL SPARK PLUG (for Bank 1)

    Click here

11. INSTALL IGNITION COIL ASSEMBLY (for Bank 1)

    Click here

12. INSTALL SPARK PLUG (for Bank 2)

    Click here

13. INSTALL IGNITION COIL ASSEMBLY (for Bank 2)

    Click here

14. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH

    Note

    Before installation, check that there is no foreign matter on the camshaft timing exhaust gear assembly LH and exhaust camshaft LH.

    
    

    1. 

       Text in Illustration

       *1	Knock Hole
       *2	Knock Pin

       Install the camshaft timing exhaust gear assembly LH while aligning the knock hole of the camshaft timing exhaust gear assembly LH with the knock pin of the exhaust camshaft LH.

    2. 

       Using SST, hold the camshaft timing exhaust gear assembly LH, and tighten the 3 bolts with a socket "TORX" wrench E16.

       SST

       09960-10010   ( 09962-01000, 09963-00700 )

       Torque:

       18 N*m  { 184 kgf*cm, 13 ft.*lbf }

15. INSTALL CAMSHAFT TIMING INTAKE GEAR ASSEMBLY LH

    Note

    Before installation, check that there is no foreign matter on the camshaft timing intake gear assembly LH and intake camshaft LH.

    
    

    1. 

       Text in Illustration

       *1	Knock Hole
       *2	Knock Pin

       Install the camshaft timing exhaust gear assembly LH while aligning the knock hole of the camshaft timing intake gear assembly LH with the knock pin of the intake camshaft LH.

    2. 

       Using SST, hold the camshaft timing intake gear assembly LH, and tighten the 3 bolts with a socket "TORX" wrench E16.

       SST

       09960-10010   ( 09962-01000, 09963-00700 )

       Torque:

       18 N*m  { 184 kgf*cm, 13 ft.*lbf }

16. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH

    Note

    Before installation, check that there is no foreign matter on the camshaft timing exhaust gear assembly RH and exhaust camshaft RH.

    
    

    1. 

       Text in Illustration

       *1	Knock Hole
       *2	Knock Pin

       Install the camshaft timing intake gear assembly RH while aligning the knock hole of the camshaft timing exhaust gear assembly RH with the knock pin of the exhaust camshaft RH.

    2. 

       Using SST, hold the camshaft timing exhaust gear assembly RH, and tighten the 3 bolts with a socket "TORX" wrench E16.

       SST

       09960-10010   ( 09962-01000, 09963-00700 )

       Torque:

       18 N*m  { 184 kgf*cm, 13 ft.*lbf }

17. INSTALL CAMSHAFT TIMING INTAKE GEAR ASSEMBLY RH

    Note

    Before installation, check that there is no foreign matter on the camshaft timing intake gear assembly RH and intake camshaft RH.

    
    

    1. 

       Text in Illustration

       *1	Knock Hole
       *2	Knock Pin

       Install the camshaft timing intake gear assembly RH while aligning the knock hole of the camshaft timing intake gear assembly RH with the knock pin of the intake camshaft RH.

    2. 

       Using SST, hold the camshaft timing intake gear assembly RH, and tighten the 3 bolts with a socket "TORX" wrench E16.

       SST

       09960-10010   ( 09962-01000, 09963-00700 )

       Torque:

       18 N*m  { 184 kgf*cm, 13 ft.*lbf }

18. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET

    
    

    1. 

       Install the crankshaft timing gear or sprocket.

19. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)

    Click here

20. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)

    Click here

21. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

    Click here

22. CONNECT ENGINE WIRE

    Click here

23. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL

    Click here

24. INSTALL CRANKSHAFT PULLEY

    Click here

25. INSTALL NO. 1 WATER BY-PASS PIPE (for Manual Transmission)

    Click here

26. INSTALL NO. 1 WATER BY-PASS PIPE (for Automatic Transmission)

    Click here

27. INSTALL REAR CYLINDER HEAD PLATE (for Manual Transmission)

    Click here

28. INSTALL VACUUM PUMP ASSEMBLY (for Automatic Transmission)

    Click here

29. INSTALL PUMP DRIVE CASE ASSEMBLY

    Click here

30. INSTALL VALVE LIFTER

    Click here

31. INSTALL FUEL PUMP ASSEMBLY

    Click here

32. INSTALL NO. 2 FUEL DELIVERY PIPE

    Click here

33. INSTALL INTAKE MANIFOLD

    Click here

34. CONNECT VENTILATION HOSE

    Click here

35. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

    Click here

36. INSTALL INJECTOR COVER (for Bank 2)

    Click here

37. INSTALL INJECTOR COVER (for Bank 1)

    Click here

38. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

39. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

    Click here

40. INSTALL OIL LEVEL DIPSTICK GUIDE

    Click here

41. INSTALL GENERATOR ASSEMBLY

    Click here

42. INSTALL FAN AND GENERATOR V BELT

    Click here

43. INSTALL BELT GENERATOR COVER

    Click here

44. INSTALL GENERATOR COVER

    Click here

45. INSTALL ENGINE HANGER

    Click here

46. REMOVE ENGINE STAND

    Click here