Part 1

1. REMOVE INTAKE AND EXHAUST CAMSHAFTS

NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be help level while it is being removed. To assist you in this, the following steps should be carried out. Should the camshaft be removed without being kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, due do the camshaft catching in this portion of the cylinder head, causing it seize or break.

A. Remove exhaust camshaft

(a) Set the knock pin of the intake camshaft at 10-45 ° BTDC of camshaft angle.

NOTE: The above angle helps to lift the exhaust camshaft level and evenly by pushing No.2 and No.4 cylinder cam lobes of the exhaust camshaft to their valve lifters.

(b) Secure the exhaust camshaft sub-gear to main gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16-20 mm (0.63-0.79 in.)

NOTE: When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the above operation.

(e) Uniformly loosen and remove bearing cap bolts 3 to 8 in several passes, in the sequence shown.

NOTE: Do not remove the No.3 bearing cap bolts at this stage.

(f) Remove the No.1, No.2 and No.4 bearing cap.

(g) Alternately loosen and remove No.3 bearing cap bolts 9 and 10.

NOTE:

- As bearing cap bolts 9 and 10 are loosened, check that the camshaft is being lifted out straight and level.
- If the camshaft is not being lifted out straight and level, tighten bearing cap bolts 9 and 10. Then reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 10-45° BTDC, and repeat the steps from (b) and (g) once again.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

(h) Remove the No.3 bearing cap and exhaust camshaft.
B. Remove intake camshaft

(a) Set the knock pin of the intake camshaft at 80-115 ° BTDC of camshaft angle.

NOTE: The above angle allows No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

(b) Remove the front bearing cap bolts 1 and 2.
(C) Remove the front bearing cap and oil seal.

CAUTION: If the front bearing cap is not removable hand, do not try to remove by force but leave as it without bolts.

(d) Uniformly loosen and remove bearing cap bolts 3 to 8 in several pass, in the sequence shown.

NOTE: Do not remove the No.2 bearing cap bolts at this stage.

(e) Remove the No.1, No.3 and No.4 bearing caps.

(f) Alternately loosen and remove No.2 bearing cap bolts 9 and 10.

NOTE:
- As bearing cap bolts 9 and 1O are loosened, check that the camshaft is being lifted out straight and level, after breaking adhesion on the front bearing cap.

- If the camshaft is not being lifted out straight and level, retighten bearing cap bolts 9 and 10. Reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 80-115° BTDC, and repeat steps from (b) to (f) once again.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

(g) Remove the No.2 bearing cap and camshaft.