Camshaft

Camshaft

REMOVAL
1) Remove the V-belt.
2) Remove the crank pulley.
3) Remove the timing belt cover.
4) Remove the timing belt assembly.
5) Remove the cam sprocket.
6) Remove the crank sprocket.





7) Remove the tensioner bracket.





8) Remove the timing belt cover No. 2 (LH).





9) Remove the timing belt cover No. 2 (RH).
10) Disconnect the ignition coil connector.
11) Remove the ignition coil.
12) Remove the rocker cover and gasket.





13) Loosen the intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
14) Remove the intake camshaft cap and intake camshaft.





15) Loosen the exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in the figure.
16) Remove the exhaust camshaft caps and exhaust camshaft.

NOTE: Arrange the camshaft caps in order so that they can be installed in their original positions.

17) Similarly, remove the camshafts (RH) and related parts.

INSTALLATION
1) Camshaft installation: Apply engine oil to the cylinder head at camshaft bearing location before installing the camshaft. Install the camshaft so that each valves is close to or in contact with "base circle" of cam lobe.

NOTE:
^ When the camshafts are positioned as shown in the figure, camshafts need to be rotated at a minimum to align with the timing belt during installation.





^ Camshaft (RH) need not be rotated when set at the position shown in the figure. Intake camshaft (LH): Rotate 80° clockwise. Exhaust camshaft (LH): Rotate 45° counterclockwise.

2) Camshaft cap installation:





a) Apply liquid gasket sparingly to the cap mating surface.

NOTE: Do not apply liquid gasket excessively. Failure to do so may cause excess packing to come out and flow toward oil seal, resulting in oil leaks.

Liquid gasket: Part No. 004403007 THREE BOND 1215 or equivalent
b) Apply engine oil to cap bearing surface and install the cap on camshaft as shown by identification mark (A).





c) Gradually tighten the camshaft cap in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque.





d) Similarly, tighten the cap on exhaust side. After tightening the cap, ensure the camshaft rotates only slightly while holding it at "base" circle.





3) Camshaft oil seal installation: Apply grease to the new oil seal lips and press onto the front end of camshaft by using ST1 and ST2.

NOTE: Use a new oil seal.

ST1 499587600 OIL SEAL INSTALLER
ST2 499597200 OIL SEAL GUIDE
4) Rocker cover installation:
a) Install the gasket on rocker cover. Install the peripheral gasket and ignition coil gasket.





b) Apply liquid gasket to the indicated portion on cylinder head and camshaft cap.
Liquid gasket: Part No. 004403007 THREE BOND 1215 or equivalent
c) Install the rocker cover on cylinder head. Ensure the gasket is properly positioned during installation.

CAUTION: Use new rocker cover gaskets.

5) Install the ignition coil.
6) Connect the ignition coil connector.
7) Similarly, install the parts on right-hand side.





8) Install the timing belt cover No. 2 (RH).
Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.)





9) Install the tensioner bracket.
Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.)





10) Install the timing belt cover No. 2 (LH).
Tightening torque: 5 Nm (0.5 kgf-m, 3.6 ft. lbs.)
11) Install the crank sprocket.
12) Install the cam sprockets.
13) Install the timing belt assembly.
14) Install the timing belt cover.
15) Install the crank pulley.
16) Install the V-belt.

INSPECTION





1) Measure the bend, and repair or replace if necessary.
Limit: 0.020 mm (0.0008 inch)
2) Check the journal for damage and wear. Replace if faulty.





3) Measure the outside diameter of camshaft journal. If the journal diameter is not as specified, check the oil clearance.
4) Measurement of the camshaft journal oil clearance:
a) Clean the bearing caps and camshaft journals.
b) Place the camshafts on cylinder head. (Without installing the valve rocker.)





c) Place a plastigauge across each of the camshaft journals.
d) Gradually tighten the cap in at least two stages in alphabetical sequence shown in the figure, and then tighten to specified torque.
Do not turn the camshaft.
Tightening torque:
T1: 9.75 Nm (1.0 kgf-m, 7.2 ft. lbs.)
T2: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.)
e) Remove the bearing caps.





f) Measure the widest point of plastigauge on each journal. If the oil clearance exceeds the standard value, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set.
Standard: 0.037 - 0.072 mm (0.0015 - 0.0028 inch)
Limit: 0.10 mm (0.0039 inch)
g) Completely remove the plastigauge.





5) Check the cam face condition; remove the minor faults by grinding with oil stone. Measure the cam height H. replace if the limit has been exceeded.
Cam height H:
Standard: Intake: 46.25 - 46.35 mm (1.821 - 1.825 inch)
Exhaust: 46.25 - 46.35 mm (1.821 - 1.825 inch)
Limit:
Intake: 46.15 mm (1.817 inch)
Exhaust: 46.15 mm (1.817 inch)
Cam base circle diameters: 37.0 mm (1.457 inch)





6) Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the standard value, replace the caps and cylinder head as a set. If necessary, replace the camshaft.
Standard: 0.068 - 0.116 mm (0.0026 - 0.0045 inch)