CAMSHAFT REMOVAL

PROCEDURE

  1. INSTALL ENGINE STAND

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  2. REMOVE ENGINE HANGER

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  3. REMOVE THROTTLE BODY ASSEMBLY

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  4. REMOVE INTAKE MANIFOLD

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  5. REMOVE DUTY VACUUM SWITCHING VALVE

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  6. REMOVE WIRE HARNESS CLAMP BRACKET

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  7. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  8. REMOVE WATER INLET HOSE

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  9. DISCONNECT NO. 3 WATER BY-PASS HOSE

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  10. REMOVE VACUUM PUMP ASSEMBLY

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  11. REMOVE NO. 1 VACUUM PUMP BRACKET

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  12. REMOVE IGNITION COIL ASSEMBLY

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  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  14. REMOVE CYLINDER HEAD COVER GASKET

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  15. REMOVE SPARK PLUG TUBE GASKET

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  16. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A294384C04

      *a

      Timing Mark

      *b

      Timing Notch

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

    2. Check that timing marks on both the camshaft timing exhaust gear assembly and camshaft timing gear assembly are facing upward as shown in the illustration.

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

  17. REMOVE CRANKSHAFT PULLEY

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  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A150854

      Remove the 2 nuts, bracket, No. 1 chain tensioner assembly and gasket.

      Note:

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

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  20. REMOVE TIMING CHAIN COVER OIL SEAL

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  21. REMOVE CHAIN TENSIONER SLIPPER

    1. A173477

      Remove the chain tensioner slipper from the cylinder block sub-assembly.

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. A165303

      Remove the 2 bolts and No. 1 chain vibration damper.

  23. REMOVE CHAIN SUB-ASSEMBLY

    1. A165304

      Hold the hexagonal portion of the camshaft with a wrench and turn the camshaft timing gear assembly counterclockwise to loosen the chain sub-assembly between the camshaft timing exhaust gear assembly and camshaft timing gear assembly.

    2. With the chain loosened, release the chain sub-assembly from the camshaft timing gear assembly and place it on the camshaft timing gear assembly.

      Tip:

      Be sure to release the chain sub-assembly from the sprocket completely.

    3. Turn the camshaft clockwise to return it to the original position and remove the chain sub-assembly.

  24. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

    1. Inspect the lock of the camshaft timing gear assembly.

    2. A173465C04

      *a

      Adhesive tape

      *b

      Adhesive tape sealing area

      *c

      Prick a hole

      After cleaning 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. A173467

      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 assembly in the advance direction (counterclockwise).

      Tip:

      Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance.

    6. A173479

      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.

  25. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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

    2. A173466C04

      *a

      Adhesive tape

      *b

      Adhesive tape sealing area

      *c

      Prick a hole

      After cleaning 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. A173468

      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 assembly in the retard direction (clockwise).

      Note:

      • Be sure to keep the camshaft timing exhaust gear assembly 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 assembly.

    6. A173480

      Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear assembly 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 assembly turns smoothly.

    7. Remove the adhesive tape from the No. 1 camshaft bearing cap.

  26. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    1. A224033C03

      *a

      Bolt

      *b

      Do not remove

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

      Note:

      • Before removing the camshaft timing gear assembly, 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.

  27. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A224036C05

      *a

      Bolt

      *b

      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.

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

    1. A199175C03

      *a

      Shim

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

      Note:

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

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

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

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

    1. A199176C05

      *a

      Hole for Engine Oil

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

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

  30. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    Note:

    • The camshaft housing sub-assembly is replaced with an assembled unit that includes the camshaft housing sub-assembly, camshafts, camshaft bearing caps, valve rocker shaft and valve rocker arm lost motion damper sub-assembly. If disassembled, replace the camshaft housing sub-assembly.

    • The camshafts cannot be replaced by themselves.

      A216395C03

      *1

      Continuously Variable Valve Lift Controller Assembly

      *2

      Camshaft Housing Sub-assembly

      *a

      Set of parts that are replaced together

      -

      -
    1. A289824N02

      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. A165298C05

      *a

      Protective Tape

      Using a screwdriver remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly.

      Tip:

      Tape the screwdriver tip before use.

      Note:

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

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

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  32. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

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  34. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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