Camshaft

Camshaft

CYLINDER HEAD AND CAMSHAFT:

Removal
1. Remove the V-belt.
2. Remove the crank pulley.
3. Remove the timing belt cover.
4. Remove the timing belt.
5. Remove the cam sprocket.
6. Disconnect the oil flow control solenoid valve assembly connector.

7. Remove the tensioner bracket.

8. Remove the timing belt cover No. 2 (LH).

9. Remove the timing belt cover No. 2 (RH).

10. Remove the spark plug cord.
11. Remove the oil level gauge guide. (LH side)
12. Remove the rocker cover and gasket.
13. Remove the oil pipe.

14. Loosen the oil flow control solenoid valve assembly and intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.

15. Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.

16. Remove the oil flow control solenoid valve assembly, intake camshaft cap, and camshaft.
17. Remove the exhaust camshaft cap and camshaft.

NOTE: Arrange the camshaft caps in order so that they can be installed in their original positions.

18. Similarly, remove the camshafts (RH) and related parts.

Installation
1. Camshaft installation
Apply engine oil to the cylinder head at camshaft bearing installing location before installing the camshaft. Install the camshaft so that each valve is close to or in contact with "base circle" of cam lobe.

NOTE:
^ When the camshafts are positioned as shown in the figure, camshaft (LH) needs to be rotated at a minimum to align with the timing belt during installation.
^ Camshaft (RH) need not be rotated when set at the position shown in the figure.

Intake camshaft (LH): Rotate 80° clockwise.
Exhaust camshaft (LH): Rotate 45° counterclockwise.

2. Camshaft cap and oil flow control solenoid valve assembly installation
a. Apply small amount of liquid gasket to the cap mating surface.

NOTE: Do not apply liquid gasket excessively. Otherwise, the excessive liquid gasket may come out and flow toward oil seal, resulting in oil leaks.

Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent

b. Apply engine oil to the cap bearing surface, and install the cap on camshaft as shown by identification mark.
c. Gradually tighten the camshaft cap and oil control valve assembly in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque.

Tightening torque:
T1: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.)
T2: 20 Nm (2.0 kgf-m, 14.8 ft. lbs.)

d. After tightening the camshaft cap, ensure the camshaft rotates only slightly while holding it at "base" circle.
3. Apply engine oil to the outer perimeter and lips of oil seal, and install the oil seal on camshaft using ST1 and ST2.

NOTE: Use a new oil seal.

ST1 499587600 OIL SEAL GUIDE
ST2 499597200 OIL SEAL GUIDE

4. Rocker cover installation
a. Install the gasket on rocker cover. Install the peripheral gasket and ignition coil gasket.
b. Apply liquid gasket to the designated point of cylinder head.

NOTE: Apply liquid gasket to the half moon plug portion with sticking out more than 5 mm (0.2 inch).

Liquid gasket. THREE BOND 1215 (Part No. 004403007) or equivalent

c. Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation.

CAUTION: Use a new rocker cover gasket.

d. Tighten the rocker cover tightening bolts in alphabetical sequence shown in the figure, and then tighten to specified torque.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)

5. Install the oil pipe.

NOTE: Installing location of the union screw varies depending on with or without filter. Be careful of this.

Tightening torque: 29 Nm (3.0 kgf-m, 21.4 ft. lbs.)

6. Connect the oil flow control solenoid valve connector.

7. Similarly, install the parts on RH side.
8. Install the timing belt cover No. 2 (RH).
Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.)

9. Install the timing belt cover No. 2 (LH).
Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.)

10. Install the tensioner bracket.
Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.)

11. Install the cam sprocket.
12. Install the timing belt.
13. Install the timing belt cover.
14. Install the crank pulley.
15. Install the V-belt.

Inspection
1. Measure the bend, and repair or replace if necessary.
Limit. 0.020 mm (0.0008 inch)

2. Check the journal for damage and wear. Replace if faulty.
3. Measure the outside diameter of camshaft journal. If the journal diameter is not within standard, check the oil clearance.

4. Measurement of the camshaft journal oil clearance
a. Clean the bearing caps and camshaft journals.
b. Place the camshafts on cylinder head. (Without installing the valve rocker.)
c. Place a plastigauge across each of the camshaft journals.
d. Gradually tighten the cap in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque. Do not turn the camshaft.
Tightening torque:
T1: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.)
T2: 20 Nm (2.0 kgf-m, 14.8 ft. lbs.)

e. Remove the bearing caps.
f. Measure the widest point of the plastigauge on each journal. If the oil clearance exceeds the limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set.
Standard. 0.037 - 0.072 mm (0. 00 15 - 0.0028 inch)
Limit: 0.10 mm (0. 0039 inch)

g. Completely remove the plastigauge.

5. Check the cam face condition, and remove the minor faults by grinding with oil stone. Measure the cam height H. If it exceeds the limit or offset wear occurs, replace the camshaft.
Cam height H.
Standard
Intake 46.55 - 46.65 mm (1.833 - 1.837 inch)
Exhaust 46.75 - 46.85 mm (1.841 - 1.844 inch)
Limit Intake 46.45 mm (1.829 inch)
Exhaust 46.65 mm (1.837 inch)
Cam base circle diameter 37.0 mm (1.457 inch)

6. Measure the thrust clearance of camshaft with dial gauge. If the thrust clearance exceeds the limit or offset wear occurs, replace the caps and cylinder head as a set. If necessary, replace the camshaft.
Standard. 0.068 - 0.116 mm (0.0027 - 0.0046 inch)
Limit. 0. 14 mm (0. 0055 inch)