Repair procedures
Removal
CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
- Mark all wiring and hoses to avoid misconnection.
- Turn the crankshaft pulley so that the No. 1 piston is at top dead center.
Timing chain cover removal is not required for this procedure.
1. Remove the cylinder head cover.
2. Set No.1 cylinder to TDC (Top dead center) on compression stroke.
(1) Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
(2) Check that the TDC marks of the intake and exhaust CVVT sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft by one revolution (360°) more.
(3) Mark the timing chains corresponding to the timing marks of the CVVT sprockets.
3. Remove the crankshaft damper pulley.
4. Remove the service plug bolt (A) with the gasket (B).
5. Remove the tensioner arm bolt (A).
6. Push down the tensioner arm (A).
7. Remove the camshaft bearing caps.
8. Remove the exhaust camshaft (A) first, then intake camshaft (B).
9. Remove the tensioner arm (A).
NOTE:
To hold the timing chain, tie it with strap.
10. Remove the CVVT assembly (A) from the camshaft.
NOTE:
When removing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.
Inspection
Camshaft
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.
If the cam lobe height is less than specification, replace the camshaft.
Cam height
Intake: 39.0 mm (1.5354 in.)
Exhaust: 38.7 mm (1.5236 in.)
2. Check the surface of the camshaft journal for wear.
If the journal is worn excessively, replace the camshaft.
3. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.
(4) Install the bearing caps and tighten the bolts with specified torque.
Tightening torque
M6 bolts:
11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)
M8 bolts:
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
CAUTION:
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
If the oil clearance is greater than specification, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
Bearing oil clearance
Standard:
0.032 - 0.062 mm (0.00126 - 0.00244 in.)
4. Inspect the camshaft end play.
(1) Install the camshaft bearing caps.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
If the end play is greater than specification, replace the camshaft.
If necessary, replace the bearing caps and cylinder head as a set
Camshaft end play
Standard:
0.10 - 0.19mm (0.0039 - 0.0075 in.)
(3) Remove the camshafts.
CVVT (Continuous Variable Valve Timing) Assembly
1. Inspect CVVT assembly.
(1) Fix the camshaft using a vise.
Be careful not to damage the cam lobe and journal.
(2) Check that the CVVT assembly will not turn.
(3) Apply vinyl tape to the retard hole like the one indicated by the arrow in the illustration.
Verify that the tape holds and put air through the port of the camshaft.
(4) Wind tape around the tip of the air gun and apply air of approx. 150 kPa (1.5 kgf/cm2, 21 psi) to the port of the camshaft.
Perform this in order to release the lock pin for the maximum delay angle locking.
NOTE:
Wrap around it with a shop rag and the likes to prevent oil from splashing.
(5) With air applied, as in step (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.
(6) Turn the CVVT assembly back and forth and check the movable range and that there is no disturbance.
Standard:
Should move smoothly in a range from about
25.0° (Intake) / 20.0° (Exhaust)
(7) Turn the intake CVVT assembly with your hand and lock it at the maximum retard angle position (counter clockwise).
(8) Turn the exhaust CVVT assembly with your hand and lock it at the maximum advance angle position (clockwise).
Installation
1. Install the CVVT assembly (A) to the camshaft.
Tightening torque :
64.7 - 76.5N.m (6.6 - 7.8kgf.m, 47.7 - 56.4lb-ft)
NOTE:
When installing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.
2. Compress the piston of the tensioner using a handy bar (A) and then insert a stopper pin (B) into the hole on the tensioner to hold the compressed piston.
3. Place the intake camshaft (A) and then insert the tensioner arm (B) along the timing chain.
4. Place the exhaust camshaft (A).
NOTE:
The timing marks of each CVVT sprocket should be matched with timing marks (painted link) of timing chain when installing the timing chain.
5. Install the camshaft bearing caps.
Tighten the bolts, in several passes, in the sequence as shown.
Tightening torque
M6 bolts:
11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)
M8 bolts:
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
NOTE:
Be careful not to change the position and direction of bearing caps.
6. Using a suitable tool, move the tensioner arm to align the tensioner bolt hole with the service hole.
7. Install the tensioner arm bolt (A).
Tightening torque:
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
8. Remove the stopper pin from the tensioner.
9. Turn the crankshaft two turns in the operating direction (clockwise), and then check that the TDC marks of the CVVT sprockets are in straight line on the cylinder head surface.
10. Install a service plug bolt (A) with a gasket.
Tightening torque:
29.4 - 39.2 N.m (3.0 - 4.0 kgf.m, 21.7 - 28.9 lb-ft)
CAUTION:
Do not reuse the service plug bolt and gasket.
11. Install the crankshaft damper pulley.
12. Install the cylinder head cover.