Camshaft: Service and Repair
CAMSHAFTREMOVAL AND INSTALLATION
Pre-removal & Post-installation Operation:
Camshaft Removal Steps 1-10,:
Camshaft Removal Steps 11-29, Intake Oil Feeder Control Valve Removal Steps 4-32, Exhaust Oil Feeder Control Valve Removal Steps 5-35:
Required Special Tool:
^ MB992103: Chain Tension Release Bar
REMOVAL SERVICE POINTS
[A] ROCKER COVER ASSEMBLY REMOVAL
Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.
[B] CYLINDER NO. 1 COMPRESSION TOP DEAD CENTER SETTING
CAUTION
Turn the crankshaft clockwise.
1. Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the cylinder No. 1 to the top dead center of compression. At this time, check that the crankshaft pulley timing mark is in the O-degree position of the ignition timing indicator of the timing chain case assembly.
2. Put paint marks on both the camshaft sprocket and timing chain at the position of camshaft sprocket timing chain mating mark (circular hole).
[C] CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL PREPARATORY OPERATION
1. Insert a precision flat-tipped screwdriver through the service hole of the timing chain case, press up the timing chain tensioner ratchet to unlock, and keep the timing chain tensioner with that state.
NOTE:
Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.
CAUTION
^ When inserting special tool MB992103 into the timing chain case assembly inside, pay attention to the position of the timing chain to avoid damage to the timing chain and timing chain tension side guide. Do not insert the special tool beyond its insertion guideline.
^ If unlocking the timing chain tensioner is insufficient, the special tool cannot be inserted to the insertion guideline. Do not insert the special tool forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool.
2. With the timing chain tensioner unlocked, insert special tool MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (Figure A).
NOTE:
With the timing chain tensioner unlocked, insert the special tool along the tension side of the timing chain, according to the special tool top shape. The special tool can be inserted smoothly to the position where the special tool insertion guide line aligns with the timing chain case assembly top surface (Figure 8), and the spread timing chain tension side guide can be held (Figure C).
3. With the special tool inserted up to the insertion guide line, press the special tool against the intake side camshaft sprocket and spread and hold the timing chain tension side guide.
4. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.
CAUTION
The timing chain may snag on by other parts. After sagging the timing chain, never rotate the crankshaft.
5. With the timing chain tension side guide spread, hook the special tool over the hexagon part of the camshaft on the exhaust side, and turn the camshaft clockwise to apply slack to the timing chain between the camshaft sprockets.
[D] FRONT CAMSHAFT BEARING CAP ASSEMBLY REMOVAL
Loosen the mounting bolts of front camshaft bearing cap in the order of number shown in the figure, and remove the front camshaft bearing cap assembly.
[E] OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL
CAUTION
When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are damaged. Always loosen the mounting bolts in four or five steps.
Loosen the mounting bolts of the camshaft bearing caps in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.
[F] CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL
1. Raise slightly the transaxle side of the camshaft and camshaft sprocket assembly (exhaust side) by using the slack of the timing chain, and remove from the cam bearing.
2. Remove the timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transaxle.
3. Remove special tool MB992103 inserted into the timing chain case assembly.
CAUTION
The timing chain may snag on other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.
4. After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the timing chain with a rope to prevent the timing chain from falling into the timing chain case assembly.
[G] CAMSHAFT SPROCKET/CAMSHAFT REMOVAL
Hold the flats of the camshaft with a monkey wrench. Loosen the camshaft sprocket mounting bolts and remove the camshaft sprocket from the camshaft.
[H] POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1. With the hose installed, remove the power steering oil pump assembly from the bracket.
2. Tie the removed power steering oil pump assembly with a string at a position where it will not interfere with the removal and installation of oil control valve.
[I] OIL FEEDER CONTROL VALVE REMOVAL
CAUTION
After removal of the oil feeder control valve, be careful to prevent dust from getting into the oil passage in the cylinder head.
INSTALLATION SERVICE POINTS
]A[ O-RING/OIL FEEDER CONTROL VALVE INSTALLATION
CAUTION
When installing the oil control valve, be careful to avoid damage to the O-ring.
Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.
]B[ CAMSHAFT/CAMSHAFT SPROCKET INSTALLATION
CAUTION
The camshaft sprocket bolt cannot be reused.
Install the camshaft and camshaft sprocket assembly as follows.
1. Check that the knock pin is set to the right overhead position.
2. an adequate and minimum amount of engine oil to the outer of the camshaft edge and the entire insertion area around camshaft sprocket assembly.
3. Set the knock pin hole of camshaft sprocket assembly to the right overhead position, and slowly insert it into the camshaft assembly to the specified position.
4. Install the camshaft sprocket to the camshaft.
5. Apply an adequate and minimum amount of engine oil to the thread of the camshaft sprocket bolt and the lower area of the flange.
6. Clamp the flats of the camshaft and fix it in the same manner as removal.
7. Tighten the camshaft sprocket bolt to the specified torque.
Tightening torque: 85 ± 5 Nm (63 ± 4 ft-lb)
]C[ CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (INTAKE SIDE) INSTALLATION
1. Align the intake side paint mark of the timing chain which was put at removal with the paint mark of the intake side camshaft sprocket, and install the camshaft sprocket to the timing chain.
2. Install the camshaft and camshaft sprocket assembly (intake side) to the cylinder head.
]D[ THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING INSTALLATION
1. Install the camshaft bearing caps to the cylinder heads.
NOTE:
Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps.
Tightening torque: 12 ± 1 Nm (107 ± 8 in-lb)
]E[ CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION
CAUTION
Be careful not to drop the camshaft bearing.
1. When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure.
2. In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner.
NOTE:
Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.
CAUTION
^ When inserting special tool MB992103 into the timing chain case assembly, pay attention to the position of the timing chain to avoid damage to the timing chain and timing chain tension side guide. Do not insert the special tool beyond its insertion guideline.
^ If unlocking the timing chain tensioner is insufficient, the special tool cannot be inserted to the insertion guideline. Do not insert the special tool forcibly, follow Step 2 again to unlock the timing chain tensioner and insert the special tool.
3. With the timing chain tensioner unlocked, insert special tool MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (Figure A).
NOTE:
With the timing chain tensioner unlocked, insert the special tool along the tension side of the timing chain, according to the special tool top shape. The special tool can be inserted smoothly to the position where the special tool insertion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.
4. With the special tool inserted up to the insertion guide line, press the special tool against the intake side camshaft sprocket (Figure B) and spread and hold the timing chain tension side guide (Figure C).
5. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.
6. Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the timing chain (Figure D) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the timing chain.
CAUTION
When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.
7. Align the exhaust side paint mark of the timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the timing chain to the camshaft sprocket.
8. Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.
9. Remove the special tool inserted into the timing chain case assembly inside.
]F[ FRONT CAMSHAFT BEARING CAP ASSEMBLY INSTALLATION
CAUTION
When the mounting bolts are tightened with the front camshaft bearing cap tilted, the front camshaft bearing cap is damaged. Install the front camshaft bearing cap properly to the cylinder head and camshaft.
1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the camshaft bearing front cap to the specified torque in the order of the figure (1).
Tightening torque: 17 ± 3 Nm (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap again to the specified torque in the order of the figure (2).
Tightening torque: 30 ± 2 Nm (23 ± 1 ft-lb)
3. After installing the front camshaft bearing cap, check that the paint marks of camshaft sprocket and of timing chain, the timing mark of crankshaft pulley, and the T-mark position of ignition timing indicator are aligned correctly.
]G[ ROCKER COVER ASSEMBLY INSTALLATION
1. Wipe off the sealant on the mating surface of the rocker cover assembly and the cylinder head and timing chain case assembly, and degrease the surface where the sealant is applied by white gasoline or the like.
2. Apply sealant to the joint between the cylinder head and timing chain case assembly as shown in the figure and install the rocker cover assembly to the cylinder head.
Specified sealant: Three bond 1217G or equivalent
NOTE:
Install the rocker cover assembly within 3 minutes after the application of sealant.
3. Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 3.0 ± 1.0 Nm (27 ± 8 in-lb)
4. Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 5.5 ± 0.5 Nm (49 ± 4 in-lb)