CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Tip:

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. 1 CAMSHAFT BEARING

    1. Clean both surfaces of the 2 No. 1 camshaft bearings.

      Note:

      Do not apply engine oil to the No. 1 camshaft bearings or the contact surfaces.

    2. Install the 2 No. 1 camshaft bearings to the camshaft bearing cap.

    3. A153839C02

      *1

      Vernier Caliper

      Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the No. 1 camshaft bearing edge.

      Difference between (A) and (B)

      0.7 mm (0.0276 in.) or less

      Note:

      Position the No. 1 camshaft bearings to the center of the camshaft bearing cap by measuring dimensions A and B.

  2. INSTALL NO. 2 CAMSHAFT BEARING

    1. Clean both surfaces of the 2 No. 2 camshaft bearings.

      Note:

      Do not apply engine oil to the No. 2 camshaft bearings or the contact surfaces.

    2. Install the 2 No. 2 camshaft bearings to the camshaft housing sub-assembly.

    3. A235863C01

      *1

      Vernier Calipers

      Using a vernier caliper, measure the distance between the camshaft bearing cap edge and the No. 2 camshaft bearing edge.

      Dimension (A)

      1.05 to 1.75 mm (0.0413 to 0.0689 in.)

      Note:

      Position the No. 2 camshaft bearings to the center of the camshaft bearing cap by measuring dimension A.

  3. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    1. Clamp the hexagonal portion of the camshaft in a soft jaw vise.

    2. Check that the straight pin is installed on the camshaft.

    3. A146265C16

      *a

      Straight Pin

      *b

      Key Groove

      Put the camshaft timing gear assembly and camshaft together with the straight pin and key groove misaligned, as shown in the illustration.

      Note:

      Do not forcibly push in the camshaft timing gear assembly. This may cause the straight pin tip to damage the installation surface of the camshaft timing gear assembly.

    4. A215319C08

      *a

      Straight Pin

      *b

      Key Groove

      Turn the camshaft timing gear assembly as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.

      Note:

      Do not turn the camshaft timing gear assembly in the retard direction.

    5. A146267C14

      *1

      Camshaft Timing Gear Assembly

      *a

      Clearance

      *b

      No Clearance

      *c

      Flange

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

    6. A235845

      Tighten the bolt with the camshaft timing gear assembly fixed in place.

      54 N*m

      551 kgf*cm

      40 ft.*lbf

      Note:

      When tightening the flange bolt, do not allow the camshaft timing gear assembly to rotate.

    7. A235846C01

      *a

      Lock

      Check that the camshaft timing gear assembly can move in the retard direction and is locked in the most retarded position.

      Tip:

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

      Click here

  4. INSTALL CAMSHAFT

    1. A131901C13

      *1

      No. 1 Valve Rocker Arm Sub-assembly

      *2

      Valve Lash Adjuster Assembly

      *3

      Valve Stem Cap

      *4

      Valve Stem

      Make sure that the No. 1 valve rocker arm sub-assembly is 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. A235859C02

      *a

      Timing Mark

      *b

      Paint Mark

      Hold up the chain sub-assembly and align the timing mark and the paint mark and install the camshaft.

      Tip:

      Perform "Inspection After Repair" after replacing the camshaft.

      Click here

  5. INSTALL NO. 2 CAMSHAFT

    1. A131901C13

      *1

      No. 1 Valve Rocker Arm Sub-assembly

      *2

      Valve Lash Adjuster Assembly

      *3

      Valve Stem Cap

      *4

      Valve Stem

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

    2. Clean the camshaft journals.

    3. Apply a light coat of engine oil to the No. 2 camshaft journals and camshaft housing sub-assembly.

    4. A235860

      Install the No. 2 camshaft to the camshaft housing sub-assembly.

      Tip:

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

      Click here

  6. INSTALL CAMSHAFT BEARING CAP

    1. Check the marks and numbers on the camshaft bearing caps, and then remove the service bolts and spacers in the order shown in the illustration. Immediately after removing the service bolts and spacers, install the camshaft bearing caps with the 15 bolts in the order shown in the illustration.

      A296689C01

      *a

      The removal order of the Service Bolts and Spacers for temporarily tightening the Camshaft Housing Sub-assembly

      *b

      The installation order of the parts

      *c

      Service Bolt and Spacer (Used to temporarily secure the Camshaft Housing Sub-assembly)

      *d

      Timing Mark

      *e

      Paint Mark

      *f

      Straight Pin

      27 N*m

      275 kgf*cm

      20 ft.*lbf

      Note:

      If the bolts are loosened all at once, FIPG on the camshaft housing sub-assembly and cylinder head sub-assembly may peel off, resulting in oil oozing. Therefore, be sure to remove the service bolts and spacers from one camshaft bearing cap at a time.

      Tip:

      Make sure that the orientation of the straight pin, timing mark and paint mark of the camshaft are as shown in the illustration.

    2. A239131N04

      Tighten the 10 bolts in the order shown in the illustration.

      16 N*m

      163 kgf*cm

      12 ft.*lbf

    3. Check the torque of each bolt again.

  7. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. A235680C02

      *a

      Timing Mark

      *b

      Paint Mark

      Hold the hexagonal portion of the camshaft with a wrench and turn it slightly counterclockwise to release the chain sub-assembly.

    2. Install the bolt to the camshaft timing exhaust gear assembly.

    3. Align the paint mark with the timing mark to install the chain sub-assembly.

      Note:

      • Do not turn the camshaft more than necessary.

      • Do not install the camshaft timing exhaust gear assembly to the No. 2 camshaft in this step. Make sure to only install the chain sub-assembly to the camshaft timing exhaust gear assembly.

    4. A215318C09

      *a

      Straight Pin

      *b

      Key Groove

      Put the camshaft timing exhaust gear assembly and No. 2 camshaft together by aligning the key groove and straight pin.

      Note:

      • If the straight pin cannot be aligned with the key groove, hold the hexagonal portion of the No. 2 camshaft with a wrench and turn it slightly to install the camshaft timing exhaust gear assembly.

      • Do not turn the No. 2 camshaft more than necessary.

      • Do not forcibly push in the camshaft timing exhaust gear assembly. This may cause the straight pin tip to damage the installation surface of the camshaft timing exhaust gear assembly.

    5. A296709C01

      *1

      Bolt

      *a

      Turn

      *b

      Hold

      Using SST and a wrench, hold the hexagonal portion of the No. 2 camshaft and install the camshaft timing exhaust gear assembly to the No. 2 camshaft.

      09249-37010

      without SST

      54 N*m

      551 kgf*cm

      40 ft.*lbf

      with SST

      39 N*m

      398 kgf*cm

      29 ft.*lbf

      Note:

      • The "with SST" torque value can be obtained by using a torque wrench with a fulcrum length of 260 mm (10.24 in.) and SST of 100 mm (3.94 in.).

        Click here

      • This torque value is effective when SST is parallel to the torque wrench.

      Tip:

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

      Click here

  8. INSTALL NO. 2 CHAIN VIBRATION DAMPER

    1. Using SST, install the No. 2 chain vibration damper to the camshaft bearing cap with the 2 bolts.

      09961-00950

      without SST

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      with SST

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

      Note:

      • The "with SST" torque value can be obtained by using a torque wrench with a fulcrum length of 180 mm (7.09 in.) and SST of 150mm (5.91 in.)

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      • This torque value is effective when SST is parallel to the torque wrench.

  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

    Click hereClick here

  10. SET NO. 1 CYLINDER TO TDC / COMPRESSION

    1. A404240C01

      *a

      Timing Mark

      *b

      Timing Notch

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

    2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are aligned as shown in the illustration.

      If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

  11. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  12. INSTALL AIR TUBE

    1. Install the air tube with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    2. Connect the vacuum hose assembly, 2 fuel vapor feed hoses and vacuum transmitting hose and slide the 3 clips to secure them.

  13. INSTALL ENGINE WIRE

    1. A294011N01

      Install the engine wire with the 3 bolts.

      Bolt A

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

      Bolt B

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. Connect the 6 connectors and 3 clamps.

  14. INSTALL NO. 2 VENTILATION HOSE

    1. Connect the No. 2 ventilation hose to the cylinder head cover sub-assembly, and slide the clamp to secure it.

  15. INSTALL IGNITION COIL ASSEMBLY

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  16. INSTALL NO. 2 CYLINDER HEAD COVER

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  17. INSTALL OUTER COWL TOP PANEL (for Sedan)

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  18. INSTALL OUTER COWL TOP PANEL (for Hatchback, Wagon)

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