CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform inspection after repair after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly or camshaft timing exhaust gear assembly.

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PROCEDURE


  1. INSTALL NO. 2 CAMSHAFT BEARING

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  2. INSTALL NO. 1 CAMSHAFT BEARING

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  3. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B0087R1C34
      *a Knock Pin
      *b Knock Pin Hole

      Align and fit the knock pin of the No. 2 camshaft to the knock pin hole of the camshaft timing exhaust gear assembly.

    2. B0088VHC03
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration and check that the camshaft timing exhaust gear assembly does not rotate.

      SST
      09212-31010

      Note


      • Do not damage the No. 2 camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    3. B0085ZHC92
      *1 Camshaft Timing Exhaust Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Clearance
      *d No Clearance

      Check that there is no clearance between the camshaft timing exhaust gear assembly and camshaft flange.

    4. While securely holding the No. 2 camshaft, install the bolt of the camshaft timing exhaust gear assembly by hand.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Do not disassemble the camshaft timing exhaust gear assembly.

      Tech Tips

      Perform inspection after repair after replacing the camshaft timing exhaust gear assembly.

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


      1. Make sure that the camshaft timing exhaust gear assembly is locked.

        Note

        Be careful not to damage the No. 2 camshaft.

    6. Release the lock pin.

      B0088T4C31
      *a Retard Side Path *b Advance Side Path
      *c Open *d Close
      *e Rubber Piece *f Vinyl Tape
      *g Knock Pin - -

      1. Clean the camshaft journal with non-residue solvent.

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

        Tech Tips

        There are 4 oil paths in the grooves of the No. 2 camshaft. Plug 3 of the oil paths with rubber pieces.

      3. Make a hole in the tape over the port (A) shown in the illustration.

      4. B0088WJ

        While applying approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the oil path, forcibly turn the camshaft timing exhaust gear assembly in the advance direction (counterclockwise).

        CAUTION:

        Cover the oil paths with a piece of cloth when applying air pressure to prevent oil from spraying.

        Note

        Do not allow the camshaft timing exhaust gear assembly to lock. If it locks, release the lock pin again.

        Tech Tips


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

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

    7. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing exhaust gear assembly turns smoothly.

        Note


        • Do not use air pressure to perform the smooth operation check.

        • Do not allow the camshaft timing exhaust gear assembly to lock. If it locks, release the lock pin again.

    8. Remove the vinyl tape and rubber pieces from the No. 2 camshaft.

    9. Remove the bolt and camshaft timing exhaust gear assembly.

  4. INSTALL OIL CONTROL VALVE FILTER

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  5. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B00866PC03
      *a Hexagonal Portion

      Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.

      SST
      09212-31010

      Note


      • Do not damage the No. 2 camshaft.

      • Never grip areas other than the hexagonal portion, as this may cause damage.

    2. B0088J9

      Install the camshaft timing exhaust gear assembly to the No. 2 camshaft with the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  6. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. B0089JMC08
      *a Timing Notch (Groove)

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

  7. INSTALL NO. 2 CAMSHAFT


    1. B00867BC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    4. B0087RUC11
      *a Paint Mark
      *b Timing mark

      Hold up the chain sub-assembly and align the timing mark and the paint mark, and install the No. 2 camshaft.

      Tech Tips

      Perform inspection after repair after replacing the No. 2 camshaft.

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  8. INSTALL CAMSHAFT


    1. B00867BC01
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      Make sure that the No. 1 valve rocker arm sub-assemblies are installed as shown in the illustration.

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the camshaft journals, camshaft housing sub-assembly and camshaft bearing caps.

    4. B0085K3C11
      *a Approximately 17°
      *b Knock Pin

      Install the camshaft to the camshaft housing sub-assembly as shown in the illustration.

      Tech Tips

      Perform inspection after repair after replacing the camshaft.

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  9. INSTALL CAMSHAFT BEARING CAP


    1. B00894ON01

      Confirm the marks and numbers on the No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps and place them and the No. 1 camshaft bearing cap in their proper positions and directions.

    2. B0085Y2N05

      Uniformly tighten the 10 bolts in several steps in the order shown in the illustration.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }
    3. B0085RIC03
      *1 No. 1 Camshaft Bearing Cap
      *2 No. 2 Camshaft Bearing Cap
      *3 No. 3 Camshaft Bearing Cap

      Uniformly tighten the 11 bolts in several steps in the order shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Check the torque of each bolt again.

  10. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY


    1. B0084XMC38
      *a Advanced Position
      *b Retarded Position
      *c Knock Pin Hole
      *d Alignment Mark

      Check the camshaft timing gear assembly position.

      Note


      • If the camshaft timing gear assembly is set to the advanced position, do not let the camshaft timing gear assembly rotate clockwise during installation.

      • If the camshaft timing gear assembly has rotated to the most retarded position, make sure to release the lock pin and set the camshaft timing gear assembly to the most advanced position before tightening the camshaft timing gear assembly.

    2. B00874LC02
      *a Narrow
      *b Wide

      Install the camshaft timing gear assembly as shown in the illustration.

    3. B0089DFC02
      *a Narrow
      *b Wide

      Turn the camshaft timing gear assembly approximately 180° counterclockwise.

    4. B0084RXC16
      *a Paint Mark
      *b Timing Mark

      Align the paint mark with the timing mark and install the chain sub-assembly to the camshaft timing gear assembly.

    5. B0086EEC79
      *a Knock Pin Hole
      *b Knock Pin

      Align and attach the knock pin of the camshaft with the knock pin hole of the camshaft timing gear assembly.

    6. B0085ZHC92
      *1 Camshaft Timing Gear Assembly
      *2 Camshaft Flange
      *a Incorrect
      *b Correct
      *c Gap
      *d No Gap

      Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.

    7. While securely holding the camshaft, install the bolt of the camshaft timing gear assembly by hand.

      Note

      Do not use any tools to install the bolt. If the bolt is installed using a tool, the lock pin will be damaged.

    8. If the lock pin has not been released, release it.


      1. B0088R7C11
        *a Make a Hole
        *b Adhesive Tape Sealing Area

        After cleaning the intake side VVT oil hole 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 seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

      2. Make a hole in the adhesive tape as shown in the illustration.

      3. B0084NX

        Apply approximately 200 kPa (2.0 kgf/cm2, 29 psi) of air pressure to the open hole to release the lock pin.

        Note


        • If air leaks out, reattach the adhesive tape.

        • Cover the hole with a piece of cloth when applying air pressure to prevent oil from spraying.

      4. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

        Tech Tips


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

        • If enough air pressure cannot be applied because of air leakage from the port, releasing the lock pin may be difficult.

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

    9. B0088FW

      Using a wrench to hold the hexagonal portion of the camshaft, install the bolt.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

    10. B0087W8C11
      *a Paint Mark
      *b Timing Mark

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

      Tech Tips

      Perform inspection after repair after replacing the camshaft timing gear assembly.

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  11. ADD ENGINE OIL

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  12. INSTALL TIMING CHAIN GUIDE

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  13. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B0086NPN08

      Turn the crankshaft pulley approximately 10° clockwise.

    2. Install a new gasket and the No. 1 chain tensioner assembly with the 2 bolts.

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

      Note

      Be careful not to drop the gasket inside the timing chain cover sub-assembly.

    3. Remove the pin from the stopper plate.

  14. CHECK NO. 1 CYLINDER TO TDC/COMPRESSION


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

      B00852UC12
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Timing Notch (Groove)
      *e Timing Mark "0°" - -

    2. Check that the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly are facing upward as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

  15. INSTALL TIMING CHAIN COVER PLATE


    1. Install a new gasket and the timing chain cover plate with the 4 bolts.

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

  16. INSTALL TIMING CHAIN COVER TIGHT PLUG

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  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  18. INSTALL IGNITION COIL ASSEMBLY

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  19. CONNECT ENGINE WIRE


    1. Connect the engine wire to the engine and install the bolts and nuts.

      B0083EKC01
      B0086HX Bolt B0088IO Nut
      Torque:
      (A)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      (B)
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    2. Connect the connectors and engage the clamps.

  20. CONNECT HOSES

    Engage the 3 clamps.

  21. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

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  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  23. INSPECT FOR ENGINE OIL LEAK

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  24. INSTALL INLET AIR CLEANER ASSEMBLY

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  25. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  26. INSTALL COOL AIR INTAKE DUCT SEAL

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  27. INSTALL FRONT FENDER APRON SEAL RH

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  28. INSTALL FRONT WHEEL RH

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