Camshaft: Service and Repair

CAMSHAFT





1. Inspect the cam lobes. Using a micrometer, measure the cam lobe height
Cam height
Intake: 44.518 - 44.718 mm (1.7527 - 1.7605 inch)
Exhaust: 44.418 - 44.618 mm (1.7487 - 1.7566 inch)
If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect the camshaft journal clearance.
1) Clean the bearing caps and camshaft journals.
2) Place the camshafts on the cylinder head.





3) Lay a strip of plastigage across each of the camshaft journal.
4) Install the bearing caps and tighten the bolts with specified torque

CAUTION: Do not turn the camshaft.

5) Remove the bearing caps.





6) Measure the plastigage at its widest point.
Bearing oil clearance
Standard: 0.020 - 0.061 mm (0.0008 - 0.0024 inch)
Limit: 0.1 mm 0.0039 inch)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
7) Completely remove the plastigage.
8) Remove the camshafts.
3. Inspect the camshaft end play.
1) Install the camshafts.





2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
Standard: 0.1 - 0.2 mm (0.0039 - 0.0079 inch)
If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
3) Remove the camshafts.

CVVT (CONTINUOUS VARIABLE VALVE TIMING) ASSEMBLY
1. Inspect the CVVT (Continuous Variable Valve Timing) assembly.
1) Check that the CVVT (Continuous Variable Valve Timing) assembly will not turn.





2) Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.
3) To release the CVVT lock pin, wrap some tape around the tip of an air pressure adapter and apply low air pressure (about 14 psi) to the exposed camshaft port.

NOTE: Wrap a shop towel or rag around the CVVT because residual oil may leak out of the unit when applying air pressure.





4) With low air pressure applied, turn the CVVT to the ADVANCE direction as indicated in the illustration.
- With the low air pressure applied, the CVVT should turn to the ADVANCE side.
- If too much air leaks when applying the low air pressure, the CVVT lock pin may not release and the CVVT may not turn.

5) Allow the CVVT assembly to move in the ADVANCE and DELAY directions to ensure there is no binding and that it moves freely.
Standard: Movable smoothly in the range about 20°
6) Turn the CVVT by hand and make sure it locks in the maximum delay angle position.

VALVE GUIDE





1. Using the SST (09221 - 3F100A), withdraw the old valve guide toward the bottom of cylinder head.
2. Recondition the valve guide hole of cylinder head so that it can match the newly press - fitted oversize valve guide.





3. Using the SST (09221 - 3F100 A/B), press - fit the valve guide. The valve guide must be press - fitted from the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in North
Valve guide length
Intake: 45.8 - 46.2 mm (1.8031 - 1.8189 inch)
Exhaust: 54.3 - 54.7 mm (2.1378 - 2.1535 inch)
4. After the valve guide is press - fitted, insert a new valve and check for proper stem - to - guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary.





VALVE GUIDE OVERSIZE

VALVE SEAT RING





1. Cut away the inner face of the valve seat to reduce the wall thickness.
2. Enlarge the seat ring hole of cylinder head so that matches the specified cylinder head hole inner diameter of new valve seat ring.
3. Heat the cylinder head to about 250°C(480°F) and press-fit an oversize seat ring for the cylinder head hole size.
4. Using lapping compound, lap the valve to the new seat.





VALVE SEAT RING OVERSIZE

REASSEMBLY

NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
- Replace oil seals with new ones.

1. Install the valves.
1) Install the spring seats.





2) Using the SST (09222-22001), push in a new oil seal.

NOTE: Do not reuse old valve stem oil seals. Incorrect installation of the seal could result in oil leakage past the valve guides.

3) Install the valve, valve spring and spring retainer.

NOTE: Place the valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer.





4) Using the SST (09222-28000, 09222-28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.





5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.





2. Install the MLA (Mechanical Lash Adjuster)s. Check that the MLA rotates smoothly by hand.

INSTALLATION

NOTE:
- Thoroughly clean all parts to be assembled.
- Always use a new cylinder head and manifold gasket.
- The cylinder head gasket is a metal gasket. Take care not to bend it.
- Rotate the crankshaft, set the No. 1 piston at TDC.





1. Install the cylinder head gasket (A) on the cylinder block.

NOTE: Be careful of the installation direction.

2. Place the cylinder head onto the block carefully in order to prevent damaging the gasket. If the gasket is damaged, fluid leakage could occur.
3. Install the cylinder head bolts.
1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.





2) Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque:
M10: 22.6 - 26.5 Nm (2.3 - 2.7kg-m, 16.6 - 19.5 ft. lbs.)+60° - 65° + 60° - 65°
M12: 27.5 - 31.4 Nm (2.8 - 3.2kg-m, 20.3 - 23.1 ft. lbs.)+60° - 65° + 60° - 65°





4. Install the Oil Control Valve (OCV) filter(A).
Tightening torque: 40.2 - 50.0 Nm (4.1 - 5.1 kg-m, 29.7 - 36.9 ft. lbs.)

NOTE:
- Always use a new Oil Control Valve (OCV) filter gasket.
- Keep the OCV filter clean.





5. Install the Oil Control Valve (OCV)(A).
Tightening torque: 9.8 - 11.8 Nm (1.0 - 1.2 kg-m, 7.2 - 8.7 ft. lbs.)

CAUTION:
- Do not reuse the Oil Control Valve (OCV) when dropped.
- Keep the OCV clean.
- Do not hold the Oil Control Valve (OCV) sleeve during servicing.
- When the OCV is installed on the engine, be careful not to rotate the engine while holding the yoke.

6. Install the camshafts.





1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.





2) Install the camshaft(A) and bearing caps(B).
Tightening torque: 13.7 - 14.7 Nm (1.4 - 1.5 kg-m, 10.1 - 10.8 ft. lbs.)





3) Install the timing chain auto tensioner (A).
Tightening torque: 7.8 - 9.8 Nm (0.8 - 1.0 kg-m, 5.8 - 7.2 ft. lbs.)
4) Remove the auto tensioner stopper pin(B).
7. Check and adjust valve clearance.





8. Using the SST (09221-21000), install the camshaft bearing oil seal.
9. Install the camshaft sprocket.
10. Install the cylinder head cover.





1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B).

NOTE:
- Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove.
- When installing, make sure the cylinder head cover gasket is seated securely in the corners of the recesses with no gap.





2) Apply liquid gasket to the head cover gasket at the corners of the recess.

NOTE:
- Use liquid gasket, Loctite No. 5999.
- Check that the mating surfaces are clean and dry before applying liquid gasket.
- After assembly, wait at least 30 minutes before filling the engine with oil.





3) Install the cylinder head cover(A) with the 12 bolts(B). Uniformly tighten the bolts in several passes.
Tightening torque: 7.8 - 9.8 Nm (0.8 - 1.0 kg-m, 5.8 - 7.2 ft. lbs.)
11. Install the PCV(Positive Crankcase Ventilation) hose.
12. Install the timing belt.
13. Install the intake manifold.
14. Install the exhaust manifold.





15. Install the spark plug cables.





16. Install the power steering pump bracket(A) and bolts(B, C).
Tightening torque:
Bolt (B): 34.3 - 49.0 Nm (3.5 - 5.0 kg-m, 25.3 - 36.2 ft. lbs.)
Bolt (c): 11.8 - 1 4.7 Nm (1.2 - 1.5 kg-m, 8.7 - 1 0.8 ft. lbs.)
17. Install the power steering pump.
18. Install the accelerator cable.
19. Install the brake booster hose(c).
20. Connect the hose(B) of the Purge Control Solenoid Valve (PCSV) side.





21. Connect the fuel inlet hose(A) of the delivery pipe side.
22. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.





1) Connect the Purge Control Solenoid Valve (PCSV) connector(A).
2) Connect the front heated oxygen sensor connector (A).
3) Connect the Crankshaft Position Sensor (CKP) connector(B).





4) Connect the oil pressure switch connector(c).
5) Connect the air conditioner compressor switch connector(F).
6) Connect the ground cables(D, E) to intake manifold and vehicle's body.
7) Connect the knock sensor connector(c).
8) Connect the fuel injector connectors(B).





9) Connect the Camshaft Position Sensor (CMP) connector(A).
10) Connect the Idle Speed Actuator (ISA) connector(B).





11) Connect the Throttle Position Sensor (TPS) connector (A).
12) Connect the ignition coil connector(D).
13) Connect the Engine Coolant Temperature (ECT) connector(c).
14) Connect the oil temperature sensor connector(B).





15) Connect the Oil Control Valve (OCV) connector(A).





23. Install the heater hose(A).





24. Install the upper radiator hose (A) and lower radiator hose(B).
25. Install the intake air hose and air cleaner assembly.





1) Install the air cleaner lower cover(A) and bolts(B).
Tightening torque: 7.8 - 9.8 Nm (0.8 - 1.0 kg-m, 5.8 - 7.2 ft. lbs.)
2) Install the air cleaner element.
3) Install the intake air hose (D) and air cleaner upper cover (c).
4) Install the breather hose (B) to intake air hose (D).





5) Connect the Air Flow Sensor (AFS) connector (A).





26. Install the engine cover.
Tightening torque: 3.9 - 5.9 Nm (0.4 - 0.6 kg-m, 2.9 - 4.3 ft. lbs.)





27. Install the heat shield(B) and connect the battery terminals (A) to the battery.
28. Fill with engine coolant.
29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.