CAMSHAFT > REMOVAL

for Preparation Click here



1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

  1. Remove the engine assembly with transaxle (Click here).



2. REMOVE GENERATOR ASSEMBLY


A217371

  1. Remove the 2 bolts and the generator.



3. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


A217295

  1. Remove the bolt, 2 nuts and the No. 1 exhaust manifold heat insulator.



4. REMOVE MANIFOLD STAY


A217296

  1. Remove the bolt, nut and the manifold stay.



5. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


A217297

  1. Remove the 3 bolts, 4 nuts and the exhaust manifold converter.

  1. Remove the exhaust manifold to head gasket and inlet EGR gasket from the cylinder head.



6. DISCONNECT VENTILATION HOSE


A217301

  1. Loosen the clip and disconnect the ventilation hose from the intake manifold.



7. DISCONNECT NO. 2 WATER BY-PASS HOSE


A217303

  1. Loosen the clip and disconnect the No. 2 water by-pass hose from the throttle body.



8. DISCONNECT NO. 4 WATER BY-PASS HOSE


A217299

  1. Loosen the clip and disconnect the No. 4 water by-pass hose from the EGR valve.



9. REMOVE INTAKE MANIFOLD STAY


A217305

  1. Remove the 2 bolts and the intake manifold stay.



10. REMOVE EGR PIPE CONNECTOR


A217298

  1. Remove the 4 nuts and the EGR pipe connector.

  1. Remove the 2 EGR pipe gaskets from the intake manifold and EGR valve.



11. REMOVE INTAKE MANIFOLD ASSEMBLY


A217306

  1. Remove the 5 bolts, 2 nuts and the intake manifold.



    A203451

  1. Remove the intake manifold to head gasket from the cylinder head.



    A217358

  1. Remove the EGR delivery chamber from the cylinder head.



    A203453

  1. Remove the No. 2 intake manifold to head gasket from the cylinder head.



12. REMOVE NO. 4 ENGINE WIRE


A217355

  1. Disconnect the 2 camshaft timing oil control valve connectors.

  1. Disconnect the 4 ignition coil connectors.

  1. Disconnect the 4 fuel injector connectors.

  1. Remove the ground bolt.

  1. Disengage the 7 clamps and remove the No. 4 engine wire.



13. REMOVE ENGINE OIL LEVEL DIPSTICK


14. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


A217307

  1. Remove the 2 bolts and the engine oil level dipstick guide.

  1. Remove the O-ring from the oil level dipstick guide.



15. REMOVE EGR VALVE ASSEMBLY


A217308

  1. Remove the bolt, 2 nuts and the EGR valve.

  1. Remove the EGR valve gaskets.



16. REMOVE FUEL DELIVERY PIPE


    A212201

  1. Disconnect the 4 fuel injector assembly connectors.



    A203440

  1. Remove the 2 bolts and delivery pipe together with the 4 injectors.

    NOTICE:
    Do not drop the fuel injectors when removing the fuel delivery pipe.



17. REMOVE FUEL INJECTOR ASSEMBLY


    A200111

  1. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.



    A200115

  1. For reinstallation, attach a tag or label to each injector shaft.

    NOTICE:
    Prevent entry of foreign objects by covering the fuel injectors with plastic bags.



18. REMOVE NO. 1 DELIVERY PIPE SPACER


    A212202

  1. Remove the 2 No. 1 delivery pipe spacers from the cylinder head.



19. REMOVE INJECTOR VIBRATION INSULATOR


    A212204

  1. Remove the 4 injector vibration insulators.



20. REMOVE NO. 1 IGNITION COIL

  1. Remove the 4 bolts and remove the 4 No. 1 ignition coils.



21. REMOVE VENTILATION HOSE


A217310

  1. Remove the ventilation hose from the cylinder head cover.



22. REMOVE NO. 2 VENTILATION HOSE


A217309

  1. Remove the No. 2 ventilation hose from the cylinder head cover.



23. REMOVE NO. 1 WATER BY-PASS PIPE


A217312E01

  1. Disengage the No. 2 water by-pass hose from the 3 clamps.
    Text in Illustration 
    *1
    		No. 2 Water By-Pass Hose
    *2
    		No. 1 Water By-Pass Pipe
    *3
    		Water By-Pass Hose

  1. Remove the 3 bolts.

  1. Disconnect the water by-pass hose and remove the No. 1 water by-pass pipe.



24. REMOVE NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System)


A217372

  1. Remove the 4 bolts and the No. 2 idle pulley assembly with bracket.



25. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


A217328

  1. Remove the 2 bolts and the V-ribbed belt tensioner.



26. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR


A217320

  1. Remove the 2 bolts and the 2 No. 1 crankshaft position sensors.



27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


A217323E01
Text in Illustration 
*1
Seal Washer

  1. Remove the 18 bolts, 2 seal washers and the cylinder head cover.

    NOTICE:
    Be careful not to drop any of the gaskets into the engine when removing the cylinder head cover because the gaskets may stick to the cylinder head cover.



    A217324

  1. Remove the cylinder head cover gasket.



28. REMOVE CAMSHAFT BEARING CAP OIL HOLE GASKET


    A197590

  1. Remove the 2 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.



29. REMOVE CRANKSHAFT POSITION SENSOR


A217325

  1. Remove the bolt and the crankshaft position sensor.



30. REMOVE WATER PUMP PULLEY


A217314E01

  1. Using SST, remove the 4 bolts and water pump pulley.

    SST
    09960-10010   (09962-01000, 09963-00600)



31. REMOVE CRANKSHAFT PULLEY


A217316E01

  1. Using SST, remove the crankshaft pulley bolt.

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

  1. Remove the crankshaft pulley from the crankshaft.



32. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


A217337

  1. Remove the 5 bolts and the water pump, water pump gasket from the timing chain cover.



    A217338

  1. Remove the 3 bolts and the engine mounting bracket.



    A217339E01

  1. Remove the 21 bolts and seal washer.
    Text in Illustration 
    *1
    		Seal Washer



    A217340E01

  1. Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block.
    Text in Illustration 
    *1
    		Protective Tape

    NOTICE:
    Be careful not to damage the contact surfaces of the timing chain cover, cylinder block, and cylinder head.



    A217341

  1. Remove the 2 O-rings.



    A200637

  1. Using an 8 mm socket hexagon wrench, remove the plug.



33. REMOVE TIMING CHAIN COVER OIL SEAL


    A197955E03

  1. Using a screwdriver with its tip wrapped with protective tape, remove the timing chain cover oil seal.
    Text in Illustration 
    *1
    		Protective Tape
    *2
    		Wooden Block

    NOTICE:
    Do not damage the surface of the oil seal press fit hole.



34. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


A219359E01

  1. Set the camshaft timing gear, camshaft timing exhaust gear and crankshaft in the positions (20° ATDC) shown in the illustration.
    Text in Illustration 
    *1
    		Timing Mark
    *a
    		TDC



    A197602E03

  1. Push down on the stopper plate to release the lock and push in the plunger.
    Text in Illustration 
    *1
    		Stopper Plate
    *2
    		Plunger
    V100136
    		Push



    A197601E02

  1. Pull up the stopper plate with the plunger pushed to the end and lock the plunger.
    Text in Illustration 
    *1
    		Stopper Plate



    A197603E02

  1. Insert a 3 mm (0.118 in.) diameter bar into the hole in the stopper plate and lock the plunger.
    Text in Illustration 
    *1
    		Bar



    A197604

  1. Remove the 2 nuts and the No. 1 chain tensioner.



    A200383

  1. Remove the gasket from the cylinder head.



35. REMOVE NO. 2 CHAIN VIBRATION DAMPER


A197605

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



36. REMOVE TIMING CHAIN TENSION ARM


A197606

  1. Remove the bolt and the timing chain tension arm.



37. REMOVE CHAIN SUB-ASSEMBLY

  1. Remove the chain.



38. REMOVE TIMING CHAIN GUIDE


A197607

  1. Remove the 2 bolts and the timing chain guide.



39. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY

  1. Inspect the lock of the camshaft timing gear.



    A198701E03

  1. After cleaning and degrease the VVT oil hole on the intake side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
    Text in Illustration 
    *1
    		Prick a Hole
    *2
    		Adhesive Tape
    *a
    		Adhesive Tape Sealing Area

    NOTICE:
    Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

  1. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure A).



    A198702

  1. Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the hole pricked in procedure A to release the lock pin.

    NOTICE:
    1. If air leaks out, reattach adhesive tape.
    2. Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

  1. Forcibly turn the camshaft timing gear assembly in the advance direction (counterclockwise).

    HINT:
    Depending on the air pressure applied, the camshaft timing gear assembly may turn in the advance direction without assistance by hand.



    A200382

  1. Turn the camshaft timing gear assembly within its movable range (26.5 to 28.5°) 2 or 3 times without turning it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.

  1. Remove the adhesive tape from the No. 1 camshaft bearing cap.



40. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

  1. Check the lock of the camshaft timing exhaust gear.



    A198700E03

  1. After cleaning and degrease the VVT oil hole on the exhaust side of the No. 1 camshaft bearing cap, completely seal the oil hole with adhesive tape or equivalent as shown in the illustration to prevent air from leaking.
    Text in Illustration 
    *1
    		Prick a Hole
    *2
    		Adhesive Tape
    *a
    		Adhesive Tape Sealing Area

    NOTICE:
    Be sure to seal the oil hole completely because air leaks due to insufficient sealing will prevent the lock pin from being released.

  1. Prick a hole in the tape covering the oil hole as shown in the illustration (Procedure B).



    A198703

  1. Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the hole pricked in procedure B to release the lock pin.

    NOTICE:
    1. If air leaks out, reattach adhesive tape.
    2. Cover the oil hole with a piece of cloth when applying air pressure to prevent oil from spraying.

  1. Using a screwdriver with its tip wrapped with tape, forcibly turn the camshaft timing exhaust gear in the retard direction (clockwise).

    NOTICE:
    1. Be sure to keep the camshaft timing exhaust gear in the retard direction using a screwdriver. If the gear is released, it will return to the most advanced position automatically due to force from the spring.
    2. Do not damage the camshaft timing exhaust gear.



    A198704

  1. Using a screwdriver with its tip wrapped with tape, turn the camshaft timing exhaust gear within its movable range (19 to 21°) 2 or 3 times without turning it to the most advanced position. Make sure that the camshaft timing exhaust gear turns smoothly.

  1. Remove the adhesive tape from the No. 1 camshaft bearing cap.



41. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    A197613E03

  1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing gear assembly.
    Text in Illustration 
    *a
    		Do Not Remove

    NOTICE:
    1. Before removing the camshaft timing gear, make sure that the lock pin has been released.
    2. Be sure not to remove the other 4 bolts.
    3. Keep the camshaft timing gear assembly horizontal while removing it from the camshaft.



42. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    A197612E02

  1. Remove the flange bolt while holding the hexagonal portion of the camshaft, and then remove the camshaft timing exhaust gear assembly.
    Text in Illustration 
    *a
    		Do Not Remove

    NOTICE:
    1. Be sure not to remove the other 4 bolts.
    2. Keep the camshaft timing exhaust gear assembly horizontal while removing it from the camshaft.



43. REMOVE CAMSHAFT BEARING CAP


    A197614E01

  1. Uniformly loosen and remove the 5 bearing cap bolts in the sequence shown in the illustration.



    A197615E01

  1. Uniformly loosen and remove the 15 bearing cap bolts in the sequence shown in the illustration.

    NOTICE:
    Uniformly loosen the bolts while keeping the camshaft level.

  1. Remove the 5 bearing caps.

    HINT:
    Arrange the removed parts in the correct order.



44. REMOVE NO. 2 CAMSHAFT


    A197618

  1. Remove the No. 2 camshaft.



45. REMOVE CAMSHAFT


    A197619

  1. Remove the camshaft.



46. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


A197616

  1. Remove the 16 valve rocker arms.

    HINT:
    Arrange the removed parts in the correct order.



47. REMOVE VALVE LASH ADJUSTER ASSEMBLY


A197617

  1. Remove the 16 valve lash adjusters from the cylinder head.

    HINT:
    Arrange the removed parts in the correct order.



48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    A197620

  1. Remove the 3 bolts.



    A197621E02

  1. Using a screwdriver with its tip wrapped with protective tape, remove the camshaft housing by prying between the cylinder head and camshaft housing.
    Text in Illustration 
    *1
    		Protective Tape

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



49. INSPECT CAMSHAFT


    A198697

  1. Inspect the camshaft for runout.

    1. Place the camshaft on V-blocks.

    2. Using a dial indicator, measure the circle runout at the center journal.

      Maximum circle runout:
      0.04 mm (0.00157 in.)

      If the circle runout is greater than the maximum, replace the camshaft.



    A198698

  1. Inspect the cam lobes.

    1. Using a micrometer, measure the cam lobe height.

      Standard cam lobe height:
      41.699 to 41.7989 mm (1.6417 to 1.6456 in.)

      Minimum cam lobe height:
      41.549 mm (1.6358 in.)

      If the cam lobe height is less than the minimum, replace the camshaft.



    A198699

  1. Inspect the camshaft journals.

    1. Using a micrometer, measure the journal diameter.

      Standard Journal Diameter:
      Journal Position
      		Specified Condition
      No. 1
      		34.454 to 34.470 mm (1.3565 to 1.3571 in.)
      Other
      		22.954 to 22.970 mm (0.9037 to 0.9043 in.)

      If the journal diameter is not as specified, check the camshaft oil clearance.



50. INSPECT NO. 2 CAMSHAFT


    A198697

  1. Inspect the No. 2 camshaft for runout.

    1. Place the No. 2 camshaft on V-blocks.

    2. Using a dial indicator, measure the circle runout at the center journal.

      Maximum circle runout:
      0.04 mm (0.00157 in.)

      If the circle runout is greater than the maximum, replace the No. 2 camshaft.



    A198698

  1. Inspect the cam lobes.

    1. Using a micrometer, measure the cam lobe height.

      Standard cam lobe height:
      41.000 to 41.100 mm (1.6142 to 1.6181 in.)

      Minimum cam lobe height:
      40.85 mm (1.6083 in.)

      If the cam lobe height is less than the minimum, replace the No. 2 camshaft.



    A198699

  1. Inspect the camshaft journals.

    1. Using a micrometer, measure the journal diameter.

      Standard Journal Diameter:
      Journal Position
      		Specified Condition
      No. 1
      		34.454 to 34.470 mm (1.3565 to 1.3571 in.)
      Other
      		22.954 to 22.970 mm (0.9037 to 0.9043 in.)

      If the journal diameter is not as specified, check the camshaft oil clearance.



51. INSPECT CAMSHAFT THRUST CLEARANCE

  1. Install the camshaft (Click here).



    A198669

  1. Install the No. 2 camshaft (Click here).

  1. Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth.

    Standard Thrust Clearance:
    Item
    		Specified Condition
    Intake
    		0.06 to 0.2 mm (0.00236 to 0.00787 in.)
    Exhaust
    		0.06 to 0.2 mm (0.00236 to 0.00787 in.)

    Maximum Thrust Clearance:
    Item
    		Specified Condition
    Intake
    		0.215 mm (0.00846 in.)
    Exhaust
    		0.215 mm (0.00846 in.)

    If the thrust clearance is greater than the maximum, replace the camshaft housing. If the thrust surface is damaged, replace the camshaft.



52. INSPECT CAMSHAFT OIL CLEARANCE


    A198670E02

  1. Clean the bearing caps and camshaft journals.

  1. Place the camshafts on the camshaft housing.

  1. Lay a strip of Plastigage across each of the camshaft journals.
    Text in Illustration 
    *1
    		Plastigage

  1. Install the camshaft bearing cap (Click here).

    NOTICE:
    Do not turn the camshaft.

  1. Remove the camshaft bearing cap (Click here).



    A198671E02

  1. Measure the Plastigage at its widest point.
    Text in Illustration 
    *1
    		Plastigage

    Standard Oil Clearance:
    Item
    		Specified Condition
    No. 1 camshaft journal
    		0.030 to 0.067 mm (0.00118 to 0.00264 in.)
    Other camshaft journals
    		0.030 to 0.067 mm (0.00118 to 0.00264 in.)

    Maximum Oil Clearance:
    Item
    		Specified Condition
    No. 1 camshaft journal
    		0.08 mm (0.00315 in.)
    Other camshaft journals
    		0.08 mm (0.00315 in.)

    NOTICE:
    Completely remove the Plastigage after the inspection.

    If the oil clearance is greater than the maximum, replace the camshaft. If necessary, replace the camshaft housing.



53. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    A125485

  1. Turn the roller by hand to check that it turns smoothly.

    HINT:
    If the roller does not turn smoothly, replace the valve rocker arm.



54. INSPECT VALVE LASH ADJUSTER ASSEMBLY


A109630E12

NOTICE:
  1. Keep the lash adjuster free of dirt and foreign matter.
  2. Only use clean engine oil.

  1. Place the lash adjuster into a container filled with engine oil.
    Text in Illustration 
    *1
    		Plunger
    *2
    		Check Ball
    *3
    		Low Pressure Chamber
    *4
    		High Pressure Chamber
    *a
    		Correct
    *b
    		Incorrect
    *c
    		Taper Part

  1. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

    SST
    09276-75010  

  1. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

  1. Check the movement of the plunger and bleed it.

    OK:
    Plunger moves up and down.

    NOTICE:
    When bleeding the high-pressure chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, the high-pressure chamber will not be bled.

  1. After bleeding, remove SST. Then, try to quickly and firmly press the plunger by hand.

    OK:
    Plunger is very difficult to move.

    If the result is not as specified, replace the lash adjuster.