Camshaft (RH)
REPLACEMENT1. DRAIN COOLANT
2. REMOVE V-BANK COVER SUB-ASSY
3. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
4. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
5. REMOVE INTAKE AIR SURGE TANK
6. REMOVE IGNITION COIL ASSY
7. REMOVE CYLINDER HEAD COVER SUB-ASSY
8. REMOVE FRONT WHEEL RH
9. REMOVE FRONT FENDER APRON SEAL RH
10. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
11. REMOVE VANE PUMP V BELT
12. REMOVE ENGINE MOVING CONTROL ROD
13. REMOVE ENGINE MOUNTING STAY NO.2 RH
14. REMOVE GENERATOR BRACKET NO.2
15. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
16. REMOVE TIMING BELT NO.1 COVER
17. REMOVE TIMING BELT NO.2 COVER
18. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
19. REMOVE TIMING BELT GUIDE NO.2
20. REMOVE TIMING BELT
21. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
22. REMOVE CAMSHAFT TIMING PULLEY
a. Using SST, remove the bolt and RH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
b. Using SST, remove the LH timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
HINT: Arrange the camshaft timing pulleys (RH and LH sides).
23. REMOVE TIMING BELT NO.3 COVER
24. REMOVE CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
a. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
b. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
Recommended service bolt
HINT: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the operation.
c. Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown, and remove the 5 bearing caps and camshaft.
NOTICE:
- Do not pry out the camshaft.
- Be careful no to damage the portion of the cylinder head receiving the shaft thrust.
25. REMOVE NO.2 CAMSHAFT
a. Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown, and remove the 5 bearing caps and No. 2 camshaft.
NOTICE:
- Do not pry out the camshaft.
- Be careful not to damage the portion of the cylinder head receiving the shaft thrust.
b. Remove the oil seal from the No. 2 camshaft.
26. REMOVE CAMSHAFT TIMING GEAR ASSY
NOTICE: Do not remove or install the camshaft timing gear (VVT-i) beside changing VVT-i or the camshaft.
a. Fix the hexagon wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Using a 46 mm socket wrench, remove the lock nut by turning it clockwise
NOTICE:
- Remove it under the condition that the lock pin is operated and locked at the maximum delay angle position.
- The lock nut has LH threads.
- Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.
c. Remove the camshaft VVT-i.
NOTICE: Never remove the 3 bolts on the gear.
HINT: In case of having difficulty to remove VVT-i, apply a slight hitting using a plastic-faced hammer and then remove it.
27. REPLACE CAMSHAFT
28. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Align the knock pin with knock pin groove and install VVT-i on the camshaft.
NOTICE: Install it under the condition that the lock pin is operated and locked at the maximum delay angle position.
b. Apply the engine oil on the nut, the placing surface of VVT-i and the screw portion.
NOTICE: Be sure to apply the oil otherwise the specified torque cannot be obtained. The nut must be changed to the new one when changing VVT-i.
c. Using a 46 mm socket wrench, install and tighten a new lock nut by turning it counterclockwise
Torque: 150 ± 5 Nm (1,530 ± 50 kgf-cm, 111 ± 4 ft. lbs.)
NOTICE:
- The lock nut has LH threads.
- Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.
29. REMOVE CAMSHAFT SUB GEAR
a. Fix the hexagonal wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Using SST, turn the sub-gear counterclockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
c. Using snap ring pliers, remove the snap ring.
d. Remove the wave washer, camshaft sub-gear and camshaft gear spring.
30. REPLACE NO.2 CAMSHAFT
31. INSTALL CAMSHAFT SUB GEAR
a. Fix the hexagonal wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Install the camshaft gear spring and camshaft sub-gear.
HINT: Attach the pins on the gears to the gear spring ends.
c. Install the wave washer.
d. Using snap ring pliers, install the snap ring.
e. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
f. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
NOTICE: Be careful not to damage the camshaft journals.
HINT: When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the operation.
32. INSTALL NO.2 CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
a. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Place the No. 2 camshaft at a 90° angle of timing mark (2 dot marks) on the cylinder head.
c. Apply MP grease to a new oil seal lip.
d. Install the oil seal to the camshaft.
NOTICE:
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.
e. Remove any old packing material from the contact surface.
f. Apply seal packing to the No. 1 bearing cap as shown.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: Install the No. 1 bearing cap within 5 minutes after applying seal packing. Do not put into engine oil within 2 hours after installing.
g. Install the 5 bearing caps in their proper locations.
h. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
i. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
33. INSTALL CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
a. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Align the timing marks (2 dot marks) of the camshaft drive with driven gears.
c. Place the camshaft on the cylinder head.
d. Install the 5 bearing caps in their proper locations.
e. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
f. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.
34. INSTALL TIMING BELT NO.3 COVER
a. Visually check the crack and break in the gasket of the timing belt cover.
NOTICE: If it is judged that water is entering at the visual check, repair it with seal packing when the crack length is within 2 - 3 cm (0.79 - 1.18 inch). Change the gasket when the crack length is 3 - 4 cm (1.18 - 1.57 inch) and more.
b. In case of repairing the timing belt cover gasket follow the procedure.
1. Repair the crack and break portion applying the seal packing.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: In case of applying the seal packing, apply it as wide and high as the gasket.
c. In case of replacing the timing belt cover gasket, follow the procedure.
1. Using a screwdriver and gasket scraper, remove the remained gasket.
NOTICE: Be careful not to damage the timing belt cover.
2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.
NOTICE: Affix the gasket in the center of the groove. At the corner, affix it without making the thickness of the gasket less.
HINT:
3. In case of having clearance at the joining portion of the gasket, apply the seal packing.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: In case of applying the seal packing, apply it as wide and high as the gasket.
d. Install the timing belt cover with the 6 bolts.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
35. INSTALL CAMSHAFT TIMING PULLEY
a. Pay attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.
HINT:
- Face the belt guide of the RH timing pulley toward the engine front.
- Face the belt guide of the LH timing pulley toward the engine rear.
b. Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)
NOTICE: The torque indicated is used without SST on extension tool. In case of using those extension tools, find the reading of the torque wrench by the formula.
Extended length:
SST (09249-63010) 150 mm (5.91 inch)
c. Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1275 kgf-cm, 92 ft. lbs.)
36. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
37. INSPECT TIMING BELT
38. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
39. INSTALL CHAIN TENSIONER ASSY NO.1
40. INSTALL TIMING BELT GUIDE NO.2
41. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
42. INSTALL TIMING BELT NO.2 COVER
43. INSTALL TIMING BELT NO.1 COVER
44. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
45. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
46. INSTALL ENGINE MOUNTING STAY NO.2 RH
47. INSTALL ENGINE MOVING CONTROL ROD
48. INSPECT VALVE CLEARANCE
49. ADJUST VALVE CLEARANCE
SST 09248-55040 (09248-05410, 09248-05420)
50. INSTALL VANE PUMP V BELT
51. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
52. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
53. INSTALL CYLINDER HEAD COVER SUB-ASSY
54. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
55. INSTALL INTAKE AIR SURGE TANK
56. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
57. CONNECT VACUUM HOSE
58. INSTALL FRONT SUSPENSION UPPER BRACE CENTER W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
59. INSTALL V-BANK COVER SUB-ASSY
60. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
61. ADD COOLANT
62. CHECK ENGINE COOLANT LEAK