Removal and Installation
CAMSHAFT
Removal and Installation
REMOVAL
1. Remove engine assembly from vehicle. Refer to Component.
2. Remove timing chain. Refer to Exploded View.
3. With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket.
CAUTION:
- Never loosen mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain.
- After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike the piston head.
4. Remove intake and exhaust camshaft brackets.
- Mark camshafts, camshaft brackets and bolts so placed in the same position and direction for installation.
- Equally loosen camshaft brackets and bolts in several steps in reverse order as shown in the figure.
- Lightly tapping with plastic hammer, remove camshaft bracket
(No. 1) and camshaft bracket (No. 6).
NOTE:
The bottom surface of each bracket will be stuck to cylinder head because of liquid gasket.
5. Remove camshaft.
6. Remove valve lifter.
- Identify installation positions, and store them without mixing them up.
INSPECTION AFTER REMOVAL
Camshaft Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Never support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Set dial indicator 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: 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 micrometer.
Standard cam height
Intake : 44.865 - 45.055 mm (1.7663 - 1.7738 in)
Exhaust : 43.925 - 44.115 mm (1.7293 - 1.7368 in)
Cam wear limit : 0.2 mm (0.008 in)
2. If wear exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER
- Measure the outer diameter of camshaft journal with micrometer.
Standard:
No. 1 : 25.938 - 25.955 mm (1.0212 - 1.0218 in)
No. 2, 3, 4, 5 : 25.953 - 25.970 mm (1.0218 - 1.0224 in)
CAMSHAFT BRACKET INNER DIAMETER
- Tighten camshaft bracket bolt with the specified torque. Refer to "INSTALLATION" for the tightening procedure.
- Measure the inner diameter "A" of camshaft bracket with bore gauge.
Standard : 26.000 - 26.021 mm (1.0236 - 1.0244 in)
CAMSHAFT JOURNAL OIL CLEARANCE
- (Oil clearance) = (Camshaft bracket inner diameter) � (Camshaft journal diameter).
Standard:
No. 1 : 0.045 - 0.083 mm (0.0018 - 0.0033 in)
No. 2, 3, 4, 5 : 0.030 - 0.068 mm (0.0012 - 0.0027 in)
No. 1 : 0.045 - 0.083 mm (0.0018 - 0.0033 in)
No. 2, 3, 4, 5 : 0.030 - 0.068 mm (0.0012 - 0.0027 in)
- If the calculated value out of the standard, replace either or both camshaft and cylinder head.
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
- Install dial indicator in thrust direction on front end of camshaft.
Measure the end play of dial indicator when camshaft is moved forward/backward (in direction to axis).
Standard:
0.115 - 0.188 mm (0.0045 - 0.0074 in)
- Measure the following parts if out of the standard.
- Dimension "A" for camshaft No. 1 journal
Standard : 30.500 - 30.548 mm (1.2008 - 1.2027 in)
- Dimension "B" for cylinder head No. 1 journal bearing
Standard : 30.360 - 30.385 mm (1.1953 - 1.1963 in)
- Refer to the standards above, and then replace camshaft and/or cylinder head.
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Never support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Measure the camshaft sprocket runout with dial indicator. (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. Refer to Testing and Inspection.
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
- Measure the outer diameter of valve lifter with micrometer.
Standard : 33.977 - 33.987 mm (1.3377 - 1.3381 in)
VALVE LIFTER HOLE DIAMETER
- Measure the inner diameter of valve lifter hole of cylinder head with inside micrometer.
Standard : 34.000 - 34.016 mm (1.3386 - 1.3392 in)
VALVE LIFTER CLEARANCE
- (Valve lifter clearance) = (Valve lifter hole diameter) � (Valve lifter outer diameter)
Standard : 0.013 - 0.039 mm (0.0005 - 0.0015 in)
- If the calculated value is out of the standard, referring to 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 if removed.
- Install it in the original position.
2. Install camshafts.
- Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction.
- Install camshaft so that dowel pin on front end face are positioned as shown in the figure. (No. 1 cylinder TDC on its compression stroke)
NOTE:
Though camshaft does not stop at the position as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
Camshaft dowel pin : At cylinder head upper face side in each bank
3. Install camshaft brackets.
- Remove foreign material completely from camshaft bracket backside and from cylinder head installation face.
- Install by referring to installation location mark on upper surface and front mark.
- Install so that installation location mark can be correctly read when viewed from the side of left exhaust bank.
- Apply liquid gasket to mating surface of camshaft bracket (No.
1) as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
- After installation, be sure to wipe off any excessive liquid gasket leaking from part "A" and "B" (both on right and left sides).
- Remove completely any excess of liquid gasket inside bracket.
- Apply liquid gasket to mating surface of camshaft bracket (No.
6) on left bank intake as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to Recommended Chemical Products and Sealants.
CAUTION:
- After installation, be sure to wipe off any excessive liquid gasket leaking from part "A" and "B" (both on right and left sides).
- Remove completely any excess of liquid gasket inside bracket.
4. Tighten camshaft bracket bolts in the following steps, in numerical order as shown in the figure.
a. Tighten No. 9 to 12 in numerical order as shown.
Torque: 1.96 N�m (0.20 kg-m, 1 ft-lb)
b. Tighten No. 1 to 8 in numerical order as shown.
Torque: 1.96 N�m (0.20 kg-m, 1 ft-lb)
c. Tighten No. 13 to 14 in numerical order as shown. (left bank only)
Torque: 1.96 N�m (0.20 kg-m, 1 ft-lb)
d. Tighten all bolts in numerical order as shown.
Torque: 5.88 N�m (0.60 kg-m, 4 ft-lb)
e. Tighten No. 1 to 12 in numerical order as shown.
Torque: 10.41 N�m (1.1 kg-m, 8 ft-lb)
f. Tighten No. 13 to 14 in numerical order as shown. (left bank only)
Torque: 31.35 N�m (3.2 kg-m, 23 ft-lb)
CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts listed below.
- Mating surface of rocker cover
- Mating surface of front cover
5. Install camshaft sprockets.
- Install by checking with identification mark on surface.
- Install camshaft sprocket (EXH) by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.)
- Lock the hexagonal part of camshaft in the same way as for removal, and tighten mounting bolts.
6. Check and adjust the valve clearance. Refer to Testing and Inspection.
7. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
- Perform this inspection only when DTC P0011 and/or P0021 are detected in self-diagnostic results of
CONSULT-III and it is directed according to inspection procedure of EC section. Refer to P0011.
- Check when the engine is cold so as to prevent burns from any splashing engine oil.
1. Check the engine oil level. Refer to Testing and Inspection.
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a. Release fuel pressure. Refer to Testing and Inspection.
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to Exploded View.
4. Crank the engine, and then check that engine oil comes out from intake valve timing control cover oil hole. End crank after checking.
WARNING:
Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.).
CAUTION:
Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. Use a shop cloth to prevent the engine components and the vehicle.
Never allow engine oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe off any splashed engine oil.
- Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from intake valve timing control cover oil hole. Refer to Lubrication Circuit.
5. 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. Refer to Lubrication Circuit.
6. After inspection, install removed parts.
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- 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/installation, slack in guide may generate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
- Bleed air from lines and hoses of applicable lines, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
