Camshaft

Camshaft





Camshaft and Associated Parts

Disassembly

CAUTION: Do not loosen except center fixing bolt of camshaft drive gear pulley.

1. Remove timing belt.
2. Remove the cap of camshaft drive pulley.





3. Remove camshaft drive pulley assembly.
4. Remove retainer.
5. Remove oil pipe.
6. Remove plug tower packing.





7. Remove sixteen fixing bolts from intake and exhaust camshaft bracket on one side bank, then camshaft brackets (2).
8. Remove camshaft assembly (3), (4) with camshaft end plug.





9. Remove high pressure fuel pump drive gear.





10. Remove camshaft rotor.
11. Use the snap ring pliers to remove the snap ring (1).





12. Remove the wave washer (2), sub gear (3) and spring camshaft gear (4) from the camshaft assembly (5).

Inspection and Repair





1. Use a micrometer to measure the cam lobe height and uneven wear. Replace the camshaft if either the lobe height or the uneven wear exceeds the specified limit.
Lobe Height
Intake: 46.9 - 47.01 mm (1.8465 - 1.8504 inch)
Exhaust: 46.35 - 46.45 mm (1.8248 - 1.8287 inch)
Minimum Cam Lobe Height
Intake: 46.75 mm (1.8406 inch)
Exhaust: 46.2 mm (1.8189 inch)





2. Use a micrometer to measure the diameter and the uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the uneven wear exceeds the specified limit.
Journal Diameter
Standard: 25.972 mm - 25.993 mm (1.0225 inch - 1.0233 inch)
If the journal diameter is not as specified.
Check the oil clearance.





3. Place the camshaft on V-blocks.
Slowly rotate the camshaft and measure the runout with a dial indicator.
Replace the camshaft if the runout exceeds the specified limit.
Runout
Limit: 0.06 mm (0.0024 inch)
4. Measure the camshaft journal oil clearance.





1. Measure the camshaft bracket housing inside diameter.
Torque: 10 Nm (7.4 ft. lbs.)

Note: Tighten camshaft bracket (2) to specified torque before measuring the camshaft bracket inside diameter.





2. Subtract the camshaft outside diameter from the camshaft bracket housing inside diameter.
Oil Clearance
Standard: 0.027 mm - 0.078 mm (0.0011 inch - 0.0031 inch)
Limit: 0.11 mm (0.0043 inch)
5. If the oil clearance exceeds the specified limit, replace the camshaft.
If necessary, replace the cylinder head.
1. Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head.





2. Install camshaft assembly and camshaft brackets (2), tighten sixteen bolts (1) on one side bank to the specified torque.
Torque: 10 Nm (7.4 ft. lbs.)





3. Measure the camshaft thrust clearance with a dial indicator. Replace the camshaft and/or the cylinder head if the camshaft thrust clearance exceeds the specified limit.
Camshaft thrust
Clearance
Standard: 0.03 mm - 0.08 mm (0.0012 inch - 0.0031 inch)
Limit: 0.12 mm (0.0047 mm)

Reassembly





1. Install the spring; camshaft gear (1) into the camshaft assembly.
Ensure the clearance is between the right side of the spring; camshaft gear (1) and the dowel pin (2).
2. Align the dowel pin on the sub gear to the clearance of the spring; camshaft gear made in step 1 and install the sub gear (3).





3. Install the wave washer (2). Use snap ring pliers to install the snap ring (1).





4. Tighten sub gear setting bolt.
a. Use J-7624 gear spring lever to pre-load the sub gear. Turn the sub gear in a clockwise direction until the M5 bolt hole aligns with the hole in the camshaft driven gear.
b. Install the M5 bolt and tighten to a suitable torque to prevent the sub gear from moving.
5. Install camshaft assembly and camshaft brackets, tighten sixteen bolts on one side bank to the specified torque.
1. Apply engine oil to camshaft journal and bearing surface of camshaft bracket.











2. Align timing mark on exhaust camshaft (one dot for right bank, two dots for left bank) and intake camshaft.





3. Apply liquid gasket (TB1207B or the equivalent to the mating surfaces of the cam bracket and the cylinder head. Immediately install the cam bracket to the cylinder head. Do not allow the liquid gasket to protrude from the journals.





4. Tighten sixteen bolts on numerical order an one side bank as shown in the illustration.
Torque: 10 Nm (74 ft. lbs.)





6. Install the oil pipe. Pay careful attention to installation direction.
Torque: 12 Nm (8.9 ft. lbs.)
7. Install plug tower packing.





8. If the oil seal requires replacement, use the J-26508 to install the oil seal.
9. Install retainer and tighten three bolts to the specified torque.
1. Install the O-ring to the cam bracket retainer.





2. Apply liquid gasket (TB1207B or the equivalent) to the O-ring areas indicated by the arrows in the illustration.
3. Tighten three bolts to the specified torque.
Torque: 10 Nm (7.4 ft. lbs.)





10. Tighten bolt for high pressure fuel pump drive gear.
Torque: 52 Nm (38.4 ft. lbs.)





11. Tighten bolt for camshaft rotor.
Torque: 52 Nm (38.4 ft. lbs.)





12. Tighten bolt for camshaft drive gear pulley.
Torque: 78 Nm (57.5 ft. lbs.) with Oil
13. Install center cap of camshaft drive gear pulley.
Torque: 15 Nm (11.1 ft. lbs.)