CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tip:

Perform "Inspection After Repairs" after replacing the camshaft, No. 2 camshaft, camshaft timing gear assembly and camshaft timing exhaust gear assembly.

PROCEDURE

  1. INSTALL NO. 2 CAMSHAFT BEARING

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  2. INSTALL NO. 1 CAMSHAFT BEARING

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  3. INSTALL OIL CONTROL VALVE FILTER

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  4. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft timing exhaust gear assembly.

    1. A196902C13

      *1

      Knock Pin Hole

      *2

      Knock Pin

      Align and attach the knock pin of the No. 2 camshaft with the knock pin hole of the camshaft timing exhaust gear assembly.

    2. A196904C37

      *1

      Camshaft Timing Exhaust Gear

      *2

      Clearance

      *3

      Camshaft Flange

      *a

      INCORRECT

      *b

      CORRECT

      *c

      No Clearance

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

    3. A250991

      Fix the camshaft timing exhaust gear assembly with the bolt.

      85 N*m

      867 kgf*cm

      63 ft.*lbf

      Note:

      Do not disassemble the camshaft timing exhaust gear.

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. A252819C05

      *1

      Timing Notch (Groove)

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

  6. INSTALL NO. 2 CAMSHAFT

    Tip:

    Perform "Inspection After Repairs" after replacing the No. 2 camshaft.

    1. A196911C21

      *1

      Valve Rocker Arm

      *2

      Valve Lash Adjuster

      *3

      Valve Stem Cap

      Make sure that the valve rocker arms 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 housings and camshaft bearing caps.

    4. A250992C05

      *1

      Paint Mark

      *2

      Matchmark

      Hold up the chain and align the matchmark and the paint mark and install the No. 2 camshaft.

  7. INSTALL CAMSHAFT

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft.

    1. A196911C21

      *1

      Valve Rocker Arm

      *2

      Valve Lash Adjuster

      *3

      Valve Stem Cap

      Make sure that the valve rocker arms 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 housings and camshaft bearing caps.

    4. A251007C05

      *1

      Knock Pin

      *a

      Approximately 17°

      Install the camshaft to the camshaft housing as shown in the illustration.

  8. INSTALL CAMSHAFT BEARING CAP

    1. A250994

      Confirm the marks and numbers on the camshaft bearing caps and place them in their proper positions and directions.

    2. A284106N05

      Using several steps, uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.

      27 N*m

      275 kgf*cm

      20 ft.*lbf

    3. A284105N05

      Using several steps, uniformly tighten the 11 bearing cap bolts in the sequence shown in the illustration.

      16 N*m

      163 kgf*cm

      12 ft.*lbf

    4. Check the torque of each bearing cap bolt again.

  9. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Tip:

    Perform "Inspection After Repairs" after replacing the camshaft timing gear assembly.

    1. A284096C07

      *1

      Knock Pin Hole

      *2

      Alignment Mark

      *a

      Advanced Position

      *b

      Retarded Position

      Check the camshaft timing gear position.

      Note:

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

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

    2. A251004C05

      *1

      Narrow

      *2

      Wide

      Install the camshaft timing gear as shown in the illustration.

    3. A250998C05

      *1

      Narrow

      *2

      Wide

      Turn the camshaft timing gear approximately 180° counterclockwise.

    4. A250999C05

      *1

      Paint Mark

      *2

      Matchmark

      Align the paint mark with the matchmark to install the chain.

    5. A196901C25

      *1

      Knock Pin Hole

      *2

      Knock Pin

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

    6. A196904C38

      *1

      Camshaft Timing Gear

      *2

      Clearance

      *3

      Camshaft Flange

      *a

      INCORRECT

      *b

      CORRECT

      *c

      No Clearance

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

    7. Secure the camshaft in place by hand, and then install the installation bolt of the camshaft timing gear 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. A249942C05

        *a

        Adhesive Tape Sealing Area

        *b

        Make a Hole

        After cleaning and degreasing the intake side VVT oil hole on the 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 covering the oil hole as shown in the illustration. (Procedure A)

      3. A251001

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

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

        Tip:

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

      5. Remove the adhesive tape from the camshaft bearing cap.

    9. A249935

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

      85 N*m

      867 kgf*cm

      63 ft.*lbf

      Note:

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

    10. A252822C04

      *1

      Paint Mark

      *2

      Matchmark

      Check that each matchmark of the camshaft timing gear and camshaft timing exhaust gear are aligned with each matchmark located as shown in the illustration.

  10. ADD ENGINE OIL

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  11. INSTALL TIMING CHAIN GUIDE

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  12. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    1. A245327C14

      *a

      Approximately 10°

      Turn the crankshaft approximately 10° clockwise.

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      Make sure not to drop the gasket inside the timing chain cover.

    3. Remove the pin from the stopper plate.

  13. 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 are aligned.

      A292248C04

      *1

      Timing Mark

      *2

      Timing Notch (Groove)

      *a

      Approximately 7°

      *b

      Approximately 32°

    2. Check that the timing marks of the camshaft timing gears are as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

      Tip:

      "A" is not a timing mark.

  14. INSTALL TIMING CHAIN COVER PLATE

    1. A250986E02

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

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      Using a 10 mm union nut wrench, tighten the A bolts. Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a union nut wrench.

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  15. INSTALL TIMING CHAIN COVER TIGHT PLUG

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  16. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  17. INSTALL CRANKSHAFT POSITION SENSOR

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  18. INSTALL IGNITION COIL ASSEMBLY

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  19. CONNECT ENGINE WIRE

    1. A296902N01

      Connect the connectors and clamps, and install the engine wire to the engine with the bolts and nuts.

      Nut A

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

      Nut B

      7.7 N*m

      79 kgf*cm

      68 in.*lbf

      Bolt

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  20. CONNECT RADIATOR RESERVOIR ASSEMBLY

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  21. INSTALL AIR CLEANER CASE

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  22. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  23. 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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  24. INSPECT FOR OIL LEAK

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  25. INSTALL REAR ENGINE UNDER COVER RH

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  26. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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