Removal And Installation

CAMSHAFT

Removal and Installation


WARNING:
- Put a "CAUTION: FLAMMABLE" sign in the workshop.
- Be sure to work in a well ventilated area and furnish workshop with a fire extinguisher.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Release the fuel pressure. Testing and Inspection.
2.Disconnect negative battery terminal. Removal and Replacement.
3.Remove front RH wheel. Adjustment.
4.Remove front fender protector (RH).
5.Drain engine coolant.
NOTE:
Perform this step when engine is cold.
6.Remove the following parts.
- Intake manifold.
- Rocker cover.
- Fuel tube and fuel injector assembly.
- Front cover, timing chain and related parts.
- Generator. Service and Repair.
7.Remove camshaft position sensor (PHASE) from camshaft bracket.

CAUTION:
- Handle carefully to avoid dropping and shocks.
- Do not disassemble.
- Do not allow metal powder to adhere to magnetic part at sensor tip.
- Do not place sensor in a location where it is exposed to magnetism.





8.Put matching marks (A) on the camshaft sprocket (INT) (2) and the camshaft bracket (1) as shown.





NOTE:
It prevents the knock pin of the camshaft (INT) from engaging with the incorrect pin hole when installing the camshaft sprocket (INT).
9.Remove camshaft sprockets (INT) (1) and (EXH) (2).





- Secure hexagonal part (A) of camshaft with a wrench. Loosen camshaft sprocket bolts and remove camshaft sprocket.

CAUTION:
- Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.
- Do not loosen the bolts with securing anything other than the camshaft hexagonal part or with tensioning the timing chain.





10.Loosen bolts in reverse order as shown.










11.Cut liquid gasket by prying the position () shown, and then remove the camshaft bracket.






CAUTION:
- Be careful not to damage the mating surface.
- A more adhesive liquid gasket is applied during initial assembly. Pry only at positions shown.
12.Remove camshafts.
13.Remove valve lifters, if necessary.
NOTE:
Identify installed positions, and store them without mixing them up.

INSPECTION AFTER REMOVAL

Camshaft Runout





1.Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft.

CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2.Set dial indicator (A) vertically to No. 3 journal.
3.Turn camshaft to one direction with hands, and measure the camshaft runout on 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 (A).

Standard:
Intake: 44.605 - 44.795 mm (1.7560 - 1.7635 in)
Exhaust: 43.175 - 43.365 mm (1.6997 - 1.7072 in)
Limit:
Intake: 44.405 mm (1.7482 in)
Exhaust: 42.975 mm (1.6919 in)

2.If it exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER





Measure the outer diameter of camshaft journal with a micrometer (A).
Standard:
No. 1: 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5: 24.950 - 24.970 mm (0.9823 - 0.9831 in)

CAMSHAFT BRACKET INNER DIAMETER
- Tighten camshaft bracket bolts with specified torque.





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





Standard:
No. 1: 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5: 25.000 - 25.021 mm (0.9843 - 0.9851 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, 5: 0.030 - 0.071 mm (0.0012 - 0.0028 in)
Limit:
: 0.15 mm (0.0059 in)

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

NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play
1.Install camshaft in cylinder head.





2.Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator (A) when camshaft is moved forward/backward (in direction to axis).

Standard: 0.075 - 0.153 mm (0.0030 - 0.0060 in)
Limit: 0.24 mm (0.0094 in)





- Measure the following parts if out of the standard.
- Dimension (A) for groove of cylinder head No. 1 journal
Standard: 4.000 - 4.030 mm (0.1575 - 0.1587 in)
- Dimension (B) for camshaft flange
Standard: 3.877 - 3.925 mm (0.1526 - 0.1545 in)
- Apply the standards above, and then replace camshaft and/or cylinder head, if necessary.
Camshaft Sprocket Runout
1.Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.

CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.





2.Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit: 0.15 mm (0.0059 in)
- If it exceeds the limit, replace camshaft sprocket.
Valve Lifter





Check if surface of valve lifter has any wear or cracks.
- If anything above is found, replace valve lifter. Testing and Inspection.
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER





- Measure the outer diameter of valve lifter with a micrometer (A).

Standard:
Intake: 33.977 - 33.987 mm (1.3377 - 1.3381 in)
Exhaust: 29.977 - 29.987 mm (1.1802 - 1.1806 in)

VALVE LIFTER HOLE DIAMETER





Measure the diameter of valve lifter hole of cylinder head with an inside micrometer (A).
Standard:
Intake: 34.000 - 34.021 mm (1.3386 - 1.3394 in)
Exhaust: 30.000 - 30.021 mm (1.1811 - 1.1819 in)

VALVE LIFTER CLEARANCE
- (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter)
Standard: 0.013 - 0.044 mm (0.0005 - 0.0017 in)
- If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.

INSTALLATION

1.Install valve lifters.
- Install them in the original positions.
2.Install camshafts.
- Clean camshaft journal to remove any foreign material.





- Distinguish between the intake and the exhaust by looking at the different shapes of the front and rear ends of the camshaft or using the identification colors (A) and (B).














- Install camshafts so that camshaft dowel pins (A) on the front side are positioned as shown.





NOTE:
Though camshaft does not stop at the positions as shown, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction as shown.
3.Remove foreign material completely from camshaft bracket backside and from cylinder head installation face.
4.Apply liquid gasket (A) to camshaft bracket as shown.





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

Tool number WS-39930000 (-)










5.Install camshaft bracket bolts in three stages in numerical order as shown.

White arrow indicates : Engine front

- There are two types of bolts. Locate the bolts as shown.
M6 bolts [thread length: 57.5 mm (2.264 in)]
: 13, 14 and 15
M6 bolts [thread length: 35.00 mm (1.378 in)]
: Except the above

6.Tighten all bolts in numerical order in three steps.
Step 1: 1.96 Nm (0.20 kg-m, 17 in-lb)
Step 2: 5.88 Nm (0.60 kg-m, 52 in-lb)
Step 3: 9.5 Nm (0.97 kg-m, 84 in-lb)





7.Install the camshaft sprocket (INT) (2) to the camshaft (INT).

NOTE:
Align the matching mark (A) applied during removal. Securely align the knock pin and the pin hole, and then install them.





8.Tighten camshaft (INT) sprocket bolt.
Camshaft sprocket bolt (INT): 35.0 Nm (3.6 kg-m, 26 ft-lb)
NOTE:
Secure the hexagonal part of camshaft (INT) using wrench to tighten bolt.





9.Turn 67 degrees clockwise (angle tightening) using Tool (B).






CAUTION:
Do not judge by visual inspection without an angle wrench.
Tool number: KV-10112100 (BT-8653-A)





10.Install camshaft sprocket (EXH) (2).





Camshaft sprocket bolt (EXH): 88.2 Nm (9.0 kg-m, 65 ft-lb)

NOTE:
Secure the hexagonal part (A) of camshaft (EXH) using wrench to tighten bolt.
11.Install timing chain and related parts.
12.Inspect and adjust valve clearance. Testing and Inspection.
13.Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION

- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Fluids and Lubricants.
- 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 and 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 make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items:





Inspection of Camshaft Sprocket (INT) Oil Groove

CAUTION:
- Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT and it is directed according to inspection procedure of EC section. P0021.
- Check when engine is cold so as to prevent burns from the splashing engine oil.
1.Check engine oil level. Procedures.
2.Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a.Remove intake manifold. Component.
b.Disconnect ignition coil and injector harness connectors.
3.Remove intake valve timing control solenoid valve. Component.





4.Clean the mating area of intake valve timing control solenoid valve. Insert a clean shop cloth (with no oil adhesion) into the oil hole (A) of the cylinder head.





5.Install engine mounting bracket (RH), engine mounting insulator, and torque rod (RH) under the Step 4 condition. (With intake valve timing control solenoid valve removed, and a shop cloth inserted into the oil hole.) Component.
6.Crank engine, and then make sure that engine oil comes out from intake valve timing control solenoid valve hole (A). End cranking after checking.
- Check engine oil leakage by oil amount adhered to the shop cloth inserted into the oil hole.

WARNING:
- Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
- Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination.

CAUTION:
- Do not perform cranking without installing right engine mount bracket, right engine mount insulator, and right torque rod.
- Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7.Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head.
- Remove oil filter (for intake valve timing control), and then clean it. Component.
- Clean oil groove between oil strainer and intake valve timing control solenoid valve. [1][2]Diagrams.
8.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. [1][2]Diagrams.
9.Installation of the remaining components is in the reverse order of removal