Camshaft Gear/Sprocket: Service and Repair

Camshaft Intake and Exhaust Sprocket Replacement

Special Tools

EN-955-1 - Locking Pin

For equivalent regional tools, refer to Special Tools Tools and Equipment.

Removal Procedure

Danger:
Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.


The High Voltage Disabling procedure will perform the following tasks:


* Identify how to disable high voltage.


* Identify how to test for the presence of high voltage.


* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.


Failure to follow the procedures exactly as written may result in serious injury or death.


1. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.

2. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

3. Disable the high voltage system. Refer to High Voltage Disabling High Voltage Disabling.

4. Remove the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair.

5. Remove both camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Exhaust)Camshaft Position Actuator Solenoid Valve Replacement (Intake) Camshaft Position Actuator Solenoid Valve Replacement (Intake).

6. Remove the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement Service and Repair.

7. Loosen the coolant recovery reservoir and hand to aside. Refer to Coolant Recovery Reservoir Replacement Service and Repair

8. Adjust the engine to TDC. Refer to Camshaft Timing Chain Adjustment Camshaft Timing Chain Adjustment.




9. Remove the heater water shutoff valve inlet hose clamp (1).

10. Disconnect the heater water shutoff valve inlet hose (2) from the water pump.




11. Remove the timing chain tensioner plug (1) from the engine front cover.




12. Install a wrench (1) on the cast hexagonal portion of the intake camshaft, rotate the camshaft toward the exhaust camshaft in order to apply tension.




13. Install EN-955-1 - pin(2) to the timing chain tensioner bore (1).

14. Remove the wrench from intake camshaft.




15. Remove the 2 upper timing chain guide bolts (1).

16. Remove the upper timing chain guide (2).




17. Loosen the intake camshaft sprocket bolt (2) while holding up the hexagon of the intake camshaft with a wrench (1).

18. Loosen the exhaust camshaft sprocket bolt while holding up the hexagon of the exhaust camshaft with a wrench.




19. Remove the camshaft sprocket bolts (2) and the camshaft position exciter wheels (1).




20. Remove the camshaft sprockets (2) and timing chain (1) as one unit.

21. Remove the intake and exhaust camshaft sprocket.

22. Allow the chain to rest on the front cover.

Installation Procedure




1. Install the camshaft sprockets (2) and timing chain (1) as one unit.




2. Install the camshaft position exciter wheels (1).

Caution: Refer to Fastener Caution Fastener Caution.

3. Install the camshaft sprocket bolts (2) and tighten to 50 Nm plus 45+15 degrees (37 lb ft) plus 45+15 degrees.

4. Remove the EN-955-1 - pin.

5. Adjust the camshaft timing chain. Refer to Camshaft Timing Chain Adjustment Camshaft Timing Chain Adjustment.




6. Install the upper timing chain guide (2).

7. Install the upper timing chain guide bolts (1) and tighten to 8 Nm (71 lb in).




8. Install the timing chain tensioner plug (1) and tighten to 50 Nm (37 lb ft).

9. Install both camshaft position actuator solenoid valves. Refer to Camshaft Position Actuator Solenoid Valve Replacement (Exhaust) Camshaft Position Actuator Solenoid Valve Replacement (Exhaust)Camshaft Position Actuator Solenoid Valve Replacement (Intake) Camshaft Position Actuator Solenoid Valve Replacement (Intake).




10. Connect the heater water shutoff valve inlet hose (2) to the water pump.

11. Install the heater water shutoff valve inlet hose clamp (1).

12. Install the air conditioning compressor bracket. Refer to Air Conditioning Compressor Bracket Replacement Service and Repair.

13. Install the air conditioning and drive motor battery cooling compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement Air Conditioning and Drive Motor Battery Cooling Compressor Replacement.

14. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement Service and Repair.

15. Install the camshaft cover. Refer to Camshaft Cover Replacement Service and Repair.

16. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

17. Enable the high voltage system. Refer to High Voltage Enabling High Voltage Enabling.