CAMSHAFT REMOVAL


  1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Remove the engine assembly with transaxle Click here.

  2. REMOVE THROTTLE BODY ASSEMBLY


    1. A01IUOW

      Disconnect the throttle body connector and 2 water hoses.

    2. A01IQIG

      Remove the 2 bolts, 2 nuts and throttle body.

    3. Remove the gasket.

  3. REMOVE INTAKE MANIFOLD


    1. A01IOOC

      Remove the bolt and wire harness clamp bracket.

    2. Detach the 5 clamps and wire harness from the intake manifold.

    3. A01IR8A

      Disconnect the fuel vapor feed hose and ventilation hose.

    4. A01IQ7Q

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

    5. A01IPY1

      Remove the gasket from the intake manifold.

    6. A01IUSC

      Remove the bolt and wire harness clamp bracket from the intake manifold.

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

  4. REMOVE AIR TUBE


    1. A01IONW

      Disconnect the fuel vapor feed hose from the purge VSV.

    2. A01IN4RE01
      Text in Illustration
      *1 Union To Connector Tube Hose
      *2 Vacuum Hose
      *3 No. 2 Air Hose
      *4 No. 1 Fuel Vapor Feed Hose

      Disconnect the union to connector tube hose and vacuum hose.

    3. Disconnect the No. 2 air hose and No. 1 fuel vapor feed hose.

    4. Remove the 2 bolts and air tube.

  5. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01IU5T

      Remove the 2 nuts and wire harness clamp bracket.

  6. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A01IURWE01
      Text in Illustration
      *1 Claw

      Remove the No. 2 fuel pipe clamp.

    2. A01IUE6E01

      Wipe off any dirt on the fuel tube connector.

    3. Hold the fuel tube connector and install SST.

      SST
      09268-21010

    4. Turn SST to align the retainer inside the fuel tube connector with the chamfered part of SST.

    5. Insert SST into the fuel tube and hold it. Then push the fuel tube connector toward SST.

    6. Mount the retainer of the fuel tube connector onto the chamfered part of SST.

    7. A01IN53E17
      Text in Illustration
      *1 O-Ring
      *2 Retainer
      *3 Pipe
      *4 Nylon Tube
      *5 Fuel Tube Connector

      Slide SST and the fuel tube connector together towards the fuel tube until they make a "click" sound, and then disconnect the fuel tube.

    8. Drain the fuel remaining inside the fuel tube.

    9. Cover the fuel tube and fuel pipe with a plastic bag to protect the disconnected parts.

  7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01ISYL

      Remove the bolt and wire harness bracket.

    2. A01IUIW

      Remove the 2 bolts.

    3. A01IPXR

      Remove the bolt and fuel delivery pipe.

    4. A01IP4K

      Remove the 2 No. 1 delivery pipe spacers.

  8. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01ISFF

      Pull the 4 fuel injector assemblies out of the fuel delivery pipe.

    2. A01IPID

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

      Note

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

    3. A01ISRJ

      Remove the 4 injector vibration insulators.

  9. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01IU0I

      Remove the engine oil level dipstick.

    2. Remove the bolt and dipstick guide.

    3. Remove the O-ring from the dipstick guide.

  10. DISCONNECT NO. 3 WATER BY-PASS HOSE


    1. A01IS6M

      Disconnect the No. 3 water by-pass hose from the water inlet housing.

  11. DISCONNECT WATER INLET HOSE


    1. A01IRVB

      Disconnect the water inlet hose from the water inlet housing.

  12. REMOVE WATER INLET


    1. A01IR3Q

      Remove the 2 nuts and water inlet.

  13. REMOVE THERMOSTAT


    1. A01IU12

      Remove the thermostat.

    2. Remove the gasket from the thermostat.

  14. REMOVE VACUUM PUMP ASSEMBLY


    1. A01IRM2

      Remove the 3 bolts and vacuum pump from the engine.

    2. A01IS1I

      Remove the 2 O-rings from the vacuum pump.

  15. REMOVE NO. 1 VACUUM PUMP BRACKET


    1. A01IPRW

      Remove the 2 bolts, vacuum pump bracket and gasket.

  16. REMOVE IGNITION COIL ASSEMBLY


    1. A01IO82

      Disconnect the 4 ignition coil connectors.

    2. A01IRN7E01
      Text in Illustration
      *1 Cylinder Head Cover
      *2 Spark Plug Tube
      *3 Plug Cap

      Remove the 4 bolts and 4 ignition coils.

      Note

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

  17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01IUMW

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

    2. A01IP7C

      Remove the 3 gaskets from the camshaft bearing cap.

      Note

      As 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.

  18. REMOVE CYLINDER HEAD COVER GASKET


    1. A01IU5J

      Remove the cylinder head cover gasket.

  19. REMOVE SPARK PLUG TUBE GASKET


    1. A01IO7K

      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.

  20. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01IPJZE01
      Text in Illustration
      *1 Timing Mark
      *2 Timing Notch

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

    2. Check that timing marks on both the camshaft timing exhaust gear 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.

  21. REMOVE CRANKSHAFT PULLEY


    1. A01IUGJE01
      Text in Illustration
      *1 Hold
      *2 Turn

      Using SST, hold the crankshaft pulley and loosen the pulley bolt. Further loosen the bolt until 2 or 3 threads are screwed into the crankshaft.

      for 86 mm (3.39 in.) Bolt Pitch Type:

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

      for 64 mm (2.52 in.) Bolt Pitch Type:

      SST
      09213-54015
      09330-00021

      Tech Tips

      For the 64 mm (2.52 in.) bolt pitch type, the part number of the installation bolt for SST (crankshaft pulley holding tool) is 91551-00850 (quantity: 2).

    2. A01IQIIE01
      Text in Illustration
      *1 Hold
      *2 Turn

      Using SST and the pulley bolt, remove the crankshaft pulley and pulley bolt.

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

      Tech Tips

      Apply lubricant to the threads and end of SST.

  22. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01IUNG

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

      Note

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

  23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01IU7T

      Remove the 3 bolts and engine mounting bracket.

    2. A01IPTE

      Remove the 4 bolts and oil filter bracket.

    3. A01ISTB

      Remove the 2 O-rings.

    4. A01IQCN

      Remove the 19 bolts.

    5. A01IO3QE02
      Text in Illustration
      *1 Protective Tape

      Remove the timing chain cover by prying between the timing chain cover and cylinder head, camshaft housing, cylinder block and stiffening crankcase with a screwdriver as shown in the illustration.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

    6. A01IO6Z

      Remove the 3 O-rings.

    7. A01IORK

      Remove the 3 bolts and water pump.

    8. A01IOBZE03

      Remove the gasket.

  24. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01INFPE05
      Text in Illustration
      *1 Wooden Block
      *2 Protective Tape

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver, tap 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.

  25. REMOVE CHAIN TENSIONER SLIPPER


    1. A01IP0L

      Remove the chain tensioner slipper from the cylinder block.

  26. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01IMZ9

      Remove the 2 bolts and chain vibration damper.

  27. REMOVE CHAIN SUB-ASSEMBLY


    1. A01IN26

      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. A01IP7RE01
      Text in Illustration
      *1 Adhesive Tape Sealing Area
      *2 Prick a Hole
      *3 Adhesive Tape

      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. A01INW8

      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. A01IOAJ

      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. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


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

    2. A01IP59E01
      Text in Illustration
      *1 Adhesive Tape Sealing Area
      *2 Prick a Hole
      *3 Adhesive Tape

      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 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. A01ISUX

      Apply approximately 200 kPa (2.0 kgf/cm2, 28 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. 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 the force from the spring.

      • Do not damage the camshaft timing exhaust gear.

    6. A01IR7S

      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.

  30. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01IRY1

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

      Note


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

      • A01IPE0E02

        Be sure not to remove the other 4 bolts.

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

  31. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01ITPM

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

      Note


      • A01INM5E06

        Be sure not to remove the other 4 bolts.

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

  32. REMOVE VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY


    1. A01IT6PE01
      Text in Illustration
      *1 Shim

      Remove the 2 bolts and valve rocker arm lost motion damper.

      Note


      • Make sure the camshaft housing is installed to the cylinder head when removing or installing a valve rocker arm lost motion damper.

      • If a valve rocker arm lost motion damper is removed, do not remove the camshaft housing.

      • Do not remove the shims. If a shim is removed, replace the camshaft housing as engine malfunctions may result from irregular valve timing.

  33. INSTALL VALVE ROCKER ARM LOST MOTION DAMPER SUB-ASSEMBLY


    1. A01IS6YE01
      Text in Illustration
      *1 Hole for Engine Oil

      Install the valve rocker arm lost motion damper with the 2 bolts. Uniformly tighten the bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Add engine oil into the hole for engine oil.

  34. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Note


    • The camshaft housing is replaced with an assembled unit that includes the camshaft housing, camshafts, camshaft bearing caps, valve rocker shaft and valve rocker arm lost motion damper. Do not disassemble the camshaft housing. If disassembled, replace the camshaft housing sub-assembly.

    • The camshafts cannot be replaced by themselves.

      A01IU8FE01

    1. A01IOOEE01

      Uniformly loosen and remove the 17 bearing cap bolts in the sequence shown in the illustration.

      Note

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

    2. A01IQT4E01
      Text in Illustration
      *1 Protective Tape

      Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

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


    1. A01INKW

      Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  36. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01IUFME01

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

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


    1. A01ISJ5

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

      If the roller does not turn smoothly, replace the No. 1 valve rocker arm sub-assembly.

  38. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster free from dirt and foreign matter.

    • Only use clean engine oil.


    1. Place the lash adjuster into a container full of new engine oil.

    2. A01IOR2E02

      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 valve lash adjuster together to move the plunger up and down 5 to 6 times.

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

      OK
      Plunger moves up and down.

      Note

      When bleeding high-pressure air from the compression 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, air bleeding is not possible.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK
      Plunger can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.