Disassembly and Assembly

CAMSHAFT


Disassembly and Assembly


DISASSEMBLY






CAUTION:
Never loosen adjusting bolts (A) and mounting bolts (black color) (B) of VVEL ladder assembly. If loosened, the stroke of cam lift becomes out of adjustment. In such case, replacement of VVEL ladder assembly and cylinder head assembly is required.

NOTE:
VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.
1. Remove rocker covers (bank 1 and bank 2). Exploded View.
2. Remove VVEL actuator sub assembly as follows:

CAUTION:
VVEL actuator sub assembly and VVEL control shaft position sensor are nonreusable. Never remove them unless they are required.
a. Remove VVEL control shaft position sensor.
b. Turn control shaft to the large lift side and fix it in order to prevent the interference of the stopper surface.
- If control shaft cannot be moved, set crankshaft in position referring to the information below. (To displace cam nose)

Bank 1 : Turn 120 degrees from no. 1 cylinder at TDC
Bank 2 : No. 1 cylinder at TDC





c. Fix two flat areas (C) of control shaft with a wrench to remove mounting bolts of control shaft.

A : Bank 1
B : Bank 2
White arrow: Engine front

CAUTION:
- During the operation, never allow a wrench to interfere with other parts.
- Fix control shaft to prevent the interference of the stopper surface.
d. Remove VVEL actuator sub assembly.





- Loosen mounting bolts in the reverse order as shown in the figure.

A : Bank 2
B : Bank 1

CAUTION:
- When removing, prepare wastes because oil spills.
- When installing, be careful with VVEL actuator sub assembly (bank 2) mounting bolt No. 1 because its length is different.
e. Remove actuator bracket (rear).





- Loosen mounting bolts in the reverse order as shown in the figure.

A : Bank 1
B : Bank 2
White arrow: Engine front

3. Remove front timing chain case, camshaft sprockets, and timing chain. Exploded View.
4. Remove rear timing chain case. Exploded View.
5. Remove VVEL ladder assembly.





- Loosen mounting bolts (gold color) in the reverse order as shown in the figure.

A : Bank 1
B : Bank 2
White arrow: Engine front

CAUTION:
- Never loosen adjusting bolts and mounting bolts (black color).
- When removing VVEL ladder assembly, hold the drive shaft from below so as not to drop it.
6. Remove camshaft (EXH).
7. Remove valve lifter.
- Identify installation positions, and store them without mixing them up.





8. Remove timing chain tensioners (secondary) (1) from cylinder head.

A : Bank 1
B : Bank 2

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

NOTE:
Stopper pin should be attached when timing chain (secondary) is removed.
9. Remove oil filter from cylinder head, if necessary.

ASSEMBLY





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

A : Bank 1
B : Bank 2

- Install timing chain tensioner with its stopper pin (C) attached.
- Install timing chain tensioner with sliding part facing downward on cylinder head (bank 1), and with sliding part facing upward on cylinder head (bank 2).





2. Install oil filter (1), if removed.
- Do not project from the cylinder head (2) surface.
3. Install valve lifter.
- Install it in the original position.
4. Install camshaft (EXH).





- Distinction between camshaft (EXH) (bank 1 and bank 2) is performed with the identification mark.

White arrow: Engine front





5. Install VVEL ladder assembly as follows:





a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the cylinder head as shown in the figure.

A : Bank 1
B : Bank 2
c : [diameter]3.4 - 4.4 mm (0.134 - 0.173 in)

White arrow: Engine front

Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.





b. Tighten mounting bolts in the following step, in numerical order as shown in the figure.

A : Bank 1
B : Bank 2
White arrow: Engine front

i. Tighten bolts in numerical order as shown in the figure.

Torque: 1.96 Nm (0.20 kg-m, 1 ft-lb)

ii. Tighten bolts in numerical order as shown in the figure.

Torque: 5.88 Nm (0.60 kg-m, 4 ft-lb)

iii. Tighten bolts in numerical order as shown in the figure.

Torque: 10.4 Nm (1.1 kg-m, 8 ft-lb)





6. Measure difference in levels between front end faces of VVEL ladder assembly and cylinder head.

Standard : -0.14 to 0.14 mm (-0.0055 to 0.0055 in)

- Measure two positions (both intake and exhaust side) for a single bank.
- If the measured value is out of the standard, reinstall VVEL ladder assembly.
7. Install rear timing chain case. Exploded View.
8. Install camshaft sprockets and timing chains. Exploded View.
9. Install actuator bracket (rear) as follows:





a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the actuator bracket (rear) as shown in the figure.

A : Bank 1
B : Bank 2
c : [diameter]3.4 - 4.4 mm (0.134 - 0.173 in)
White arrow : Engine front

Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.

CAUTION:
Never apply gasket to the oil passage.





b. Tighten mounting bolts in the following steps, in numerical order as shown in the figure.

A : Bank 1
B : Bank 2
White arrow : Engine front

i. Tighten bolts in numerical order as shown in the figure.

Torque: 1.96 Nm (0.20 kg-m, 1 ft-lb)

ii. Tighten bolts in numerical order as shown in the figure.

Torque: 5.88 Nm (0.60 kg-m, 4 ft-lb)

iii. Tighten bolts in numerical order as shown in the figure.

Torque: 31.4 Nm (3.2 kg-m, 23 ft-lb)

10. Install new VVEL actuator sub assembly as follows:

CAUTION:
Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one-on-one basis, replace them as a set.

NOTE:





- VVEL actuator arm (B) is factory-fixed at 5.5 degrees from the small lift with a holding jig (A).
- The holding jig is supplied in the new VVEL actuator sub assembly.

CAUTION:





- Never disassemble VVEL actuator sub assembly. [Never loosen actuator motor mounting bolts (A) shown in the figure]
- Never shock VVEL actuator sub assembly.
a. Move control shaft to the position of small lift stopper.





- The position where a part of the stopper of control shaft contacts VVEL ladder bracket.

1 : VVEL ladder assembly (bank 2)
2 : VVEL ladder assembly (bank 1)
A : Stopper of control shaft
Black arrow: Small lift side

CAUTION:
Be careful not to damage the stopper surface.
- If control shaft cannot be moved, set crankshaft in position referring to the information below. (To displace cam nose)

Bank 1 : Turn 120 degrees from No. 1 cylinder at TDC
Bank 2 : No. 1 cylinder at TDC





b. Hold two flat areas of control shaft with a wrench, and rotate the control shaft (5.5 degrees from the stopper) to the large lift side.
(This is for aligning the bolt hole of control shaft and the hole of
VVEL actuator arm.)

1 : VVEL actuator sub assembly (bank 1)
A : Control shaft
b : 5.5 degrees
Black arrow: Large lift side





c. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to the VVEL actuator sub assembly as shown in the figure.

1 : VVEL actuator sub assembly (bank 2)
2 : VVEL actuator sub assembly (bank 1)
a : 4.0 - 5.6 mm (0.157 - 0.220 in)
b : [diameter]3.4 - 4.4 mm (0.134 - 0.173 in)

Use Genuine RTV Silicone Sealant or equivalent. Fluid Type Specifications.

CAUTION:
Never apply gasket to the oil passage.
d. Install new VVEL actuator sub assembly.





- Tighten mounting bolts in the following step, in numerical order as shown in the figure.

A : Bank 2
B : Bank 1

CAUTION:
- When installing, be careful with VVEL actuator sub assembly (bank 2) mounting bolt No. 1 because its length is different.
- Be sure to check that the VVEL actuator sub assembly is in contact with the cylinder head before tightening the mounting bolts.
e. Remove holding jig.
f. Check that VVEL actuator arm bolt hole is aligned with control shaft tapped hole. If it is not aligned, turn control shaft for alignment.





g. Fix two flat areas (C) of control shaft with a wrench to install mounting bolts of control shaft.

A : Bank 1
B : Bank 2
White arrow: Engine front

CAUTION:
- During the operation, never allow a wrench to interfere with other parts.
- Fix control shaft to prevent the interference of the stopper surface.
11. Install new VVEL control shaft position sensor as follows:

CAUTION:
Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one-on-one basis, replace them as a set.
a. Apply engine oil to O-ring or contact surface of O-ring.





b. Align matching marks (B) of VVEL control shaft position sensor and upper housing.

C : Bank 2

- Face connector toward matching mark (A).
c. Temporarily tighten bolt.
d. Adjust VVEL control shaft position sensor after setting the engine assembly in the vehicle. Description.

CAUTION:
Be sure to adjust VVEL control shaft position sensor.
e. After adjusting VVEL control shaft position sensor, tighten bolts to the specified torque.
12. Inspect the valve clearance. Service and Repair.
13. Install in the reverse order of removal after this step.