CAMSHAFT REMOVAL

PROCEDURE

1. REMOVE INLET NO. 1 AIR CLEANER

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2. REMOVE AIR CLEANER CAP SUB-ASSEMBLY

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3. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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4. REMOVE NO. 1 IGNITION COIL

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5. SEPARATE DUTY VACUUM SWITCHING VALVE

   

   1. Remove the bolt and separate the duty vacuum switching valve from the cylinder head cover sub-assembly.

6. SEPARATE ENGINE WIRE

   1. Separate the engine wire from the cylinder head cover sub-assembly.

7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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8. REMOVE CYLINDER HEAD COVER GASKET

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9. REMOVE TIMING GEAR COVER TIGHT PLUG

   1. 

      *a	8 mm Hexagon Socket Wrench

      Using an 8 mm hexagon socket wrench, remove the timing gear cover tight plug.

10. SET NO. 1 CYLINDER TO TDC/EXHAUST

    1. 

       *a	Timing Mark

       Turn the crankshaft pulley clockwise to align the timing mark of the pulley with the timing mark of the timing chain cover sub-assembly (set the No. 1 piston to TDC/exhaust).

    2. 

       *a	Timing Mark

       Make sure that the timing mark of the camshaft timing gear is at the top.

       Tip:

       If the timing mark is not at the top, turn the crankshaft pulley 1 revolution so that the timing mark comes to the top (set the No. 1 piston to TDC/exhaust).

11. REMOVE CAMSHAFT TIMING GEAR

    1. 

       *a	Paint Mark
       *b	Timing Mark

       Place paint marks on the chain plates in alignment with the timing marks of the camshaft timing gear and camshaft timing sprocket assembly.

    2. Rotate the crankshaft 90° clockwise.

       Note:

       Do not allow a lifted valve and piston to come into contact with each other when removing the camshaft.

    3. 

       *a	Hold
       *b	Turn

       Using SST, loosen the bolts of the camshaft timing sprocket assembly while holding the hexagonal portion of the camshaft.

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    4. 

       *a	Stopper Plate
       *b	Plunger

       Insert a screwdriver into the plug hole and turn the stopper plate of the No. 1 chain tensioner assembly clockwise to release the lock.

       Tip:

       • The plunger of the No. 1 chain tensioner assembly is locked.

       • If the stopper plate is locked firmly, slightly turn the hexagonal portion of the camshaft to the right and left.

    5. 

       *a	Plunger
       *b	Turn

       While ensuring that the lock remains released, slightly turn the hexagonal portion of the camshaft clockwise so that the plunger of the No. 1 chain tensioner assembly is pushed by the chain sub-assembly.

    6. 

       *a	Hexagon Wrench

       Insert a hexagon wrench into the stopper plate hole.

       Tip:

       Hold the hexagon wrench with tape so that the hexagon wrench does not come off.

    7. 

       *a	Hold
       *b	Turn

       Remove the bolt of the camshaft timing gear while holding the hexagonal portion of the No. 2 camshaft.

    8. 

       Remove the camshaft timing gear.

12. REMOVE CAMSHAFT

    1. 

       Slide the camshaft timing sprocket assembly toward the front of the engine until the No. 1 camshaft bearing cap comes off.

    2. 

       *1	No. 1 Camshaft Bearing Cap
       *2	No. 2 Camshaft Bearing Cap

       Remove the 15 bolts in the order shown in the illustration.

    3. Remove the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps.

    4. 

       Remove the camshaft.

       Tip:

       • Remove the camshaft with the camshaft timing sprocket assembly.

13. REMOVE NO. 2 CAMSHAFT

    1. 

       Remove the No. 2 camshaft.

    2. 

       Using a piece of string or equivalent, secure the chain sub-assembly to prevent it from dropping.

14. REMOVE CAMSHAFT TIMING SPROCKET ASSEMBLY

    1. 

       Remove the bolt and camshaft timing sprocket assembly.

15. INSPECT CAMSHAFT TIMING SPROCKET ASSEMBLY

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