Camshaft Removal

Temporarily install the pulley set bolt.

Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

HINT:

If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.

Remove the 2 bolts, No. 1 chain tensioner LH and gasket.

Remove the 2 bolts and No. 1 chain vibration damper LH.

While pushing down the No. 3 chain tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

1. Be careful not to damage the cylinder head with the wrench.
   
2. Do not disassemble the camshaft timing gear.
   

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

1. Be careful not to damage the cylinder head with the wrench.
   
2. Do not disassemble the camshaft timing exhaust gear.
   

Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

Remove the No. 1 and No. 2 chains from the gears.

Remove the 2 bolts and No. 3 chain tensioner.

Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.

Remove the 2 bolts and No. 1 chain tensioner RH.

Remove the 2 bolts and No. 1 chain vibration damper RH.

While raising up the No. 2 chain tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

1. Be careful not to damage the cylinder head with the wrench.
   
2. Do not disassemble the camshaft timing gear.
   

Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

Text in Illustration

*a	Hold
	Turn

NOTICE:

1. Be careful not to damage the cylinder head with the wrench.
   
2. Do not disassemble the camshaft timing exhaust gear.
   

Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

Remove the No. 1 and No. 2 chains from the gears.

Remove the 2 bolts and No. 2 chain tensioner.

Make sure that the knock pins of the camshafts are positioned as shown in the illustration.

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 6 camshaft bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 3 camshaft from the camshaft housing LH.

Remove the No. 4 camshaft from the camshaft housing LH.

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT:

Tape the screwdriver tip before use.

Make sure that the knock pins of the camshafts are positioned as shown in the illustration.

Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.

Uniformly loosen and remove the 18 bearing cap bolts in the sequence shown in the illustration.

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 6 camshaft bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the No. 1 camshaft from the camshaft housing RH.

Remove the No. 2 camshaft from the camshaft housing RH.

Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

NOTICE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT:

Tape the screwdriver tip before use.

Install the camshaft bearing cap (Click here).

HINT:

Only install the intake camshaft.

Install the camshaft housing (Click here).

HINT:

Do not use seal packing when installing the camshaft housing as the installation is temporary.

Apply a light coat of engine oil to the camshaft and camshaft timing gear.

Using the hexagonal portion of the camshaft, align the knock pin of the camshaft with the pin hole of the camshaft timing gear and install the camshaft timing gear.

NOTICE:

1. Do not forcefully push on the camshaft timing gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing gear.
   


2. Do not loosen or remove the 3 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 camshaft timing gear assembly with a new one.
   

Apply a light coat of engine oil to the threads and under the head of the bolt.

Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing gear flange bolt.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap (Click here).

Check the lock of the camshaft timing gear.

1. Clamp the camshaft in a vise and confirm that the camshaft timing gear is locked.
   

   NOTICE:

   Be careful not to damage the camshaft.

Release the lock pin.

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*a	Open
*b	Close
	Vinyl Tape

1. Clean the cam journal with non-residue solvent.
   

2. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
   

3. Break through the tape over the advance side path. Then break through the tape over the retard side path on the opposite side of the advanced side path as shown in the illustration.
   





4. Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 29 psi) to the two paths accessible through the holes in the tape.
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path

   NOTICE:

   Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.





5. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path
   *a	Decompress
   *b	Hold Pressure

   HINT:

   This operation releases the lock pin which holds the timing gear in the most retarded position.

6. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path in that order.
   

   NOTICE:

   Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

Check for smooth rotation.

1. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.
   

   NOTICE:

   Do not use air pressure to perform the smooth rotation check.

Check the lock at the most retarded position.

1. Confirm that the camshaft timing gear becomes locked at the most retarded position.
   

Install the camshaft bearing cap (Click here).

HINT:

Only install the intake camshaft.

Install the camshaft housing (Click here).

HINT:

Do not use seal packing when installing the camshaft housing as the installation is temporary.

Hold the hexagonal portion of the camshaft with a wrench and loosen the flange bolt.

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap (Click here).

Remove the flange bolt and camshaft timing gear.

Install the camshaft bearing cap (Click here).

HINT:

Only install the exhaust camshaft.

Install the camshaft housing (Click here).

HINT:

Do not use seal packing when installing the camshaft housing as the installation is temporary.

Apply a light coat of engine oil to the camshaft and camshaft timing exhaust gear.

Using the hexagonal portion of the camshaft, align the knock pin of the camshaft with the pin hole of the camshaft timing exhaust gear and install the camshaft timing exhaust gear.

NOTICE:

1. Do not forcefully push on the camshaft timing exhaust gear. This may cause the camshaft knock pin tip to damage the installation surface of the camshaft timing exhaust gear.
   


2. Do not loosen or 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 camshaft timing exhaust gear assembly with a new one.
   

Apply a light coat of engine oil to the threads and under the head of the bolt.

Using a wrench to hold the hexagonal portion of the camshaft, install the camshaft timing exhaust gear flange bolt.

Torque:

100 N*m{1020 kgf*cm, 74 ft.*lbf}

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap (Click here).

Check the camshaft timing exhaust gear lock.

1. Make sure that the camshaft timing exhaust gear is locked.
   

Release the lock pin.

Text in Illustration

*1	Advance Side Path
*2	Retard Side Path
*a	Open
*b	Close
	Vinyl Tape

1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
   

2. Break through the tape over the advance side path. Then break through the tape over the retard side path on the opposite side of the advanced side path as shown in the illustration.
   





3. Apply compressed air at approximately 200 kPa (2.0 kgf/cm², 29 psi) to the two paths accessible through the holes in the tape (the advance side path and retard side path).
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path

   NOTICE:

   Cover the paths with a piece of cloth when applying pressure to keep oil from splashing.





4. Check that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.
   

   Text in Illustration

   *1	Advance Side Path
   *2	Retard Side Path
   *a	Hold Pressure
   *b	Decompress

   HINT:

   The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.

5. When the camshaft timing exhaust gear moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.
   

   NOTICE:

   Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts.

Check for smooth rotation.

1. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.
   

   NOTICE:

   When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position, due to the advance assist spring operation, and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

Check the lock at the most advanced position.

1. Make sure that the camshaft timing exhaust gear becomes locked at the most advanced position.
   

Install the camshaft bearing cap (Click here).

HINT:

Only install the exhaust camshaft.

Install the camshaft housing (Click here).

HINT:

Do not use seal packing when installing the camshaft housing as the installation is temporary.

Hold the hexagonal portion of the camshaft with a wrench and loosen the flange bolt.

Text in Illustration

*a	Hold
	Turn

Remove the camshaft bearing cap (Click here).

Remove the flange bolt and camshaft timing exhaust gear.