Camshaft - Removal

1. Remove timing belt

2. Remove ignition coil assembly

3. Remove cylinder head cover (for rh side)

4. Remove cylinder head cover (for lh side)

5. Remove camshaft timing pulley sub-assembly rh

6. Remove camshaft timing pulley sub-assembly lh

7. Remove camshaft position sensor

8. Remove camshaft (for rh side)

9. Remove camshaft (for lh side)

10. Remove semicircular plug

11. Remove camshaft sub gear

12. Remove camshaft housing plug

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HINT:

(Click here)

1. Disconnect the 4 ignition coil connectors.

2. Remove the 4 bolts and 4 ignition coils.

1. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.

1. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket. Remove the cylinder head cover.

1. Hold the camshaft with a wrench, and remove the 4 bolts and timing pulley.

   NOTICE:

   Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.

1. Hold the camshaft with a wrench, and remove the 4 bolts and timing pulley.

   NOTICE:

   Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.

1. Remove the bolt, stud bolt and camshaft position sensor.

NOTICE:

1. As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.
   
2. Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration.
   

1. Crankshaft pulley
   

1. Bring the service bolt hole of the sub-gear upward by turning the hexagonal portion of the exhaust camshaft with a wrench.

2. Secure the sub-gear to the main gear with a service bolt.

   Recommended service bolt

   Thread diameter	6 mm
   Thread pitch	1.0 mm
   Bolt length	16 to 20 mm

   HINT:

   When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

3. Set the timing mark (1-dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagonal portion of the exhaust camshaft with a wrench.

4. Uniformly loosen and remove the 22 bearing cap bolts in several steps, in the order shown in the illustration.

5. Remove the oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter, and camshafts.

   HINT:

   Arrange the bearing caps in the correct order.

6. Mount the hexagonal portion of the camshaft in a vise.

   NOTICE:

   1. Be careful not to damage the camshaft.
      
   2. Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.
      

7. Remove the screw plug and seal washer.

8. Using a 10 mm hexagon wrench, remove the bolt.

9. Pull out the timing tube and drive gear from the camshaft.

10. Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.

    SST

    09960-10010 (09962-01000, 09963-00500)
    

    NOTICE:

    Be careful not to damage the timing tube.

NOTICE:

1. As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged. To avoid this, the following steps should be carried out.
   
2. Having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft. Always set the crankshaft pulley at the correct angle as shown in the illustration.
   

1. Bring the service bolt hole of the sub-gear upward by turning the hexagonal portion of the exhaust camshaft with a wrench.

2. Secure the sub-gear to the main gear with a service bolt.

   Recommended service bolt

   Thread diameter	6 mm
   Thread pitch	1.0 mm
   Bolt length	16 to 20 mm

   HINT:

   When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

3. Align the timing marks (2-dot marks) of the camshaft drive and driven gears by turning the hexagonal portion of the exhaust camshaft with a wrench.

4. Uniformly loosen and remove the 22 bearing cap bolts in several steps, in the order shown in the illustration.

5. Remove the oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter, and camshafts.

   HINT:

   Arrange the bearing caps in the correct order.

6. Mount the hexagonal portion of the camshaft in a vise.

   NOTICE:

   1. Be careful not to damage the camshaft.
      
   2. Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.
      

7. Remove the screw plug and seal washer.

8. Using a 10 mm hexagon wrench, remove the bolt.

9. Pull out the timing tube and drive gear assembly from the camshaft.

10. Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.

    SST

    09960-10010 (09962-01000, 09963-00500)
    

    NOTICE:

    Be careful not to damage the timing tube.

1. Mount the hexagonal portion of the camshaft in a vise.

   NOTICE:

   Be careful not to damage the camshaft.

2. Using SST, turn the sub gear clockwise and remove the service bolt.

   SST

   09960-10010 (09962-01000, 09963-00500)
   

3. Using snap ring pliers, remove the snap ring.

4. Remove the wave washer, sub gear and gear spring.

   HINT:

   Arrange the camshaft sub gears and gear spring (RH and LH sides).

5. Using a vernier caliper, measure the gap distance of the gear spring.

   Gap distance:

   18.2 to 18.8 mm (0.717 to 0.740 in.)
   

   If the gap distance is not as specified, replace the gear spring.