Removal and Installation

CAMSHAFT


Removal and Installation


REMOVAL
1. Remove front timing chain case, camshaft sprocket, and timing chain. Refer to Removal and Installation.
2. Remove fuel sub tube. Refer to Component Removal and Installation.





3. Remove camshaft sensor bracket bolts in reverse order as shown in the figure.

4. Remove intake and exhaust camshaft brackets.
- Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for installation.
- Equally loosen camshaft bracket bolts in several steps in reverse order as shown in the figure.





5. Remove camshaft.
6. Remove valve lifter.
- Identify installation positions, and store them without mixing them up.





7. Remove timing chain tensioner (secondary) (1) from cylinder head.

- Remove timing chain tensioner (secondary) with its stopper pin (C) attached.

NOTE:
Stopper pin was attached when timing chain (secondary) was removed.

INSPECTION AFTER REMOVAL

Camshaft Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft.

CAUTION:
Never support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.





2. Set dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on a dial indicator. (Total indicator reading)

Standard : Less than 0.02 mm (0.0008 in)
Limit : 0.05 mm (0.0020 in)

4. If it exceeds the limit, replace camshaft.

Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer.






Standard cam height:
Intake : 45.865 - 46.055 mm (1.8057 - 1.8132 in)
Exhaust : 45.875 - 46.065 mm (1.8061 - 1.8136 in)
Cam wear limit : 0.2 mm (0.008 in)

2. If wear is beyond the limit, replace camshaft.

Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER
- Measure the outer diameter of camshaft journal with a micrometer





(A).

Standard:
No. 1 : 25.935 - 25.955 mm (1.0211 - 1.0218 in)
No. 2, 3, 4 : 23.445 - 23.465 mm (0.9230 - 0.9238 in)


CAMSHAFT BRACKET INNER DIAMETER
- Tighten camshaft bracket bolt with the specified torque. Refer to Component for the tightening procedure.





- Measure the inner diameter "A" of camshaft bracket with a bore gauge.

Standard:
No. 1 : 26.000 - 26.021 mm (1.0236 - 1.0244 in)
No. 2, 3, 4 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)


CAMSHAFT JOURNAL OIL CLEARANCE
- (Oil clearance) = (Camshaft bracket inner diameter) � (Camshaft journal diameter)

Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4 : 0.035 - 0.076 mm (0.0014 - 0.0030 in)
Limit : 0.15 mm (0.0059 in)

- If it exceeds the limit, replace either or both camshaft and cylinder head.

NOTE:
Camshaft brackets cannot be replaced as single parts, because there are machined together with cylinder head. Replace whole cylinder head assembly.

Camshaft End Play
- Install a dial indicator in thrust direction on front end of camshaft.





Measure the end play of a dial indicator when camshaft is moved forward/backward (in direction to axis).

Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in)
Limit : 0.24 mm (0.0094 in)






- Measure the following parts if out of the limit.
- Dimension "A" for camshaft No. 1 journal

Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)

- Dimension "B" for cylinder head No. 1 journal bearing

Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)

- Refer to the standards above, and then replace camshaft and/or cylinder head.

Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journal of camshaft.

CAUTION:
Never support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.





2. Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)

Limit : 0.15 mm (0.0059 in)

- If it exceeds the limit, replace camshaft sprocket.

CAUTION:
When replacing camshaft sprocket (EXH), replace valve timing control cover (including magnet retarder and cover).

Valve Lifter
Check if surface of valve lifter has any wear or cracks.





- If anything above is found, replace valve lifter. Refer to [1][2]Specifications.

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
- Measure the outer diameter at 1/2 height of valve lifter with a micrometer (A) since valve lifter is in barrel shape.






Standard (Intake and exhaust) : 33.980 - 33.990 mm (1.3378 - 1.3382 in)


VALVE LIFTER HOLE DIAMETER
- Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer.






Standard (Intake and exhaust) : 34.000 - 34.016 mm (1.3386 - 1.3392 in)

VALVE LIFTER CLEARANCE
- (Valve lifter clearance) = (Valve lifter hole diameter) � (Valve lifter outer diameter)

Standard (Intake and exhaust) : 0.010 - 0.036 mm (0.0004 - 0.0014 in)

- If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

INSTALLATION
1. Install timing chain tensioners (secondary) (1) on both sides of cylinder head.





- Install timing chain tensioner with its stopper pin (C) attached.
- Install timing chain tensioner with sliding part facing downward on right-side cylinder head, and with sliding part facing upward on left-side cylinder head.
2. Install valve lifter.
- Install it in the original position.
3. Install camshafts.





- Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction.









- Install camshaft so that and dowel pin (A) on front end face are positioned as shown in the figure. (No. 1 cylinder TDC on its compression stroke)

NOTE:
Though camshaft does not stop at the portion as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
4. Install camshaft brackets.





- Remove foreign material completely from camshaft bracket backside and from cylinder head installation face.
- Install camshaft bracket in original position and direction as shown in the figure.





- Install camshaft brackets (No. 2 to 4) aligning the stamp marks
(A) as shown in the figure.


NOTE:
There are no identification marks indicating left and right for camshaft bracket (No. 1).





- Apply liquid gasket to mating surface of camshaft bracket (No.
1) as shown on bank 1 and bank 2.

Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.





- Apply liquid gasket to camshaft bracket (No. 1) contact surface on the rear timing chain case backside as shown on both bank
1 and bank 2.

Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.

CAUTION:
For camshaft bracket (No. 1) near installation position, and install it without disturbing the liquid gasket applied to the surfaces.
5. Tighten camshaft bracket bolts in the following steps, in numerical order as shown in the figure.
a. Tighten No. 7 to 10 in numerical order as shown.

Torque: 1.96 N�m (0.2 kg-m, 1 ft-lb)

b. Tighten No. 1 to 6 in numerical order as shown.

Torque: 1.96 N�m (0.2 kg-m, 1 ft-lb)

c. Tighten No. 1 to 10 in numerical order as shown.






Torque: 5.88 N�m (0.6 kg-m, 4 ft-lb)

d. Tighten No. 1 to 10 in numerical order as shown.

Torque: 10.4 N�m (1.1 kg-m, 8 ft-lb)


CAUTION:
After tightening mounting bolts of camshaft brackets (No.
1), be sure to wipe off excessive liquid gasket from the parts list below.
- Mating surface of rocker cover
- Mating surface of rear timing chain case
6. Inspect and adjust the valve clearance. Refer to Testing and Inspection.
7. Install camshaft sensor bracket.





- Tighten camshaft sensor bracket bolts in numerical order as shown in the figure.

NOTE:
2. The order of tightening bolts is the same for bank 1 and bank
8. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION

Inspection of Camshaft Sprocket (INT) Oil Groove

CAUTION:
- Perform this inspection only when DTC P0011 or P0021 are detected in self-diagnostic results of
CONSULT-III and it is directed according to inspection procedure of EC section. Refer to Diagnosis Description.
- Check when engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer to Testing and Inspection.
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a. Release fuel pressure. Refer to Testing and Inspection.
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to Exploded View.





4. Crank the engine, and then check that engine oil comes out from valve timing control solenoid valve hole (A). End crank after checking.


WARNING:
Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.).

CAUTION:





Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. Use a shop cloth to prevent the engine components and the vehicle. Never allow engine oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe off any splashed engine oil.
- Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from valve timing control solenoid valve hole. Refer to Lubrication Circuit.
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging.
- Clean oil groove if necessary. Refer to Lubrication Circuit.
6. After inspection, install removed parts.

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
- Bleed air from lines and hoses of applicable lines, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.