Part 2
Cam Carrier (Continued)CAM CARRIER LH
1) Insert the steel rods into ST, and set the engine so that the camshaft LH is facing up.
CAUTION:
^ If the engine is standing on one side without inserting the steel rod into ST, engine may lose balance and fall down. Be sure to insert the steel rod into ST to extend the length.
^ Use the steel rod with enough strength.
^ Be careful not to pinch the engine harness with ST.
ST 499817100 ENGINE STAND
2) Apply engine oil to the valve shim and the roller rocker arm pivot, and install the valve shim and the roller rocker arm pivot to the cylinder head LH.
3) Apply engine oil to the O-ring and the roller rocker arm, and install the O-ring and the roller rocker arm to the cylinder head LH.
NOTE:
Use new O-rings.
4) Apply liquid gasket to the mating surface of cam carrier LH as shown in the figure.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent
Liquid gasket applying diameter:
2.5±0.5 mm (0.0984±0.0197 in)
5) Install the cam carrier LH to the cylinder head LH.
(1) Mount the cam carrier LH, then tighten all bolts with a torque of 18 Nm (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure.
NOTE:
Set the intake camshaft LH and the exhaust camshaft LH to the zero-lift position.
(2) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.
(3) Tighten the bolts (3 places) with a torque of 18 Nm (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure.
(4) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.
(5) Tighten the bolts (3 places) with a torque of 18 Nm (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure.
(6) Loosen the bolts (3 places) by 180° in numerical order as shown in the figure.
(7) Tighten the bolts (3 places) with a torque of 18 Nm (1.8 kgf-m, 13.3 ft-lb) in numerical order as shown in the figure.
NOTE:
After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
6) Set the part so that the intake manifold is on the upper side.
7) Install the cam sprocket LH.
NOTE:
This procedure is required only when the cam carrier LH is removed for disassembly.
8) Check the cam clearance. Testing and Inspection
9) Install timing chain LH.
10) Install the fuel pipe LH and the fuel injector LH.
(1) Install the fuel pipe LH and the fuel injector LH, and install the bolts which secure the fuel pipe LH.
NOTE:
Use new O-rings, rubbers and seal rings.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
(2) Connect the quick connector to the fuel pipe LH.
CAUTION:
^ Check that there is no damage or dust on the quick connector. If necessary, clean the seal surface of the pipe.
^ When connecting the quick connector, make sure to insert the pipe all the way in before locking the slider.
^ If it is not possible to perform the push lock operation of the slider, recheck whether the pipe is securely inserted.
^ Make sure that the quick connector is securely connected.
NOTE:
Connect the quick connector as shown in the figure.
(3) Connect the connectors to the fuel injector LH.
11) Connect the water pipe hose to oil pan upper, and install the water pipe assembly.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
12) Connect the preheater hose to throttle body and install the preheater hose to intake manifold clip (A).
13) Secure the engine harness to the cam carrier LH with a clip.
14) Install the rocker cover LH.
15) Install the chain cover.
16) Install the engine to the vehicle.
DISASSEMBLY
CAM CARRIER RH
1) Loosen the bolts (front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH) equally, a little at a time in numerical sequence as shown in the figure, and remove the camshaft cap.
NOTE:
Arrange camshaft caps in order so that they can be installed in their original positions.
2) Remove the intake camshaft RH and the exhaust camshaft RH from cam carrier RH.
3) Remove the filter from cam carrier RH.
4) Remove the liquid gasket from cam carrier RH and front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH.
CAM CARRIER LH
1) Loosen the bolts (front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH) equally, a little at a time in numerical sequence as shown in the figure, and remove the camshaft cap.
NOTE:
Arrange camshaft caps in order so that they can be installed in their original positions.
2) Remove the intake camshaft LH and the exhaust camshaft LH from cam carrier LH.
3) Remove the filter from cam carrier LH.
4) Remove the liquid gasket from cam carrier LH and front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH.
ASSEMBLY
CAM CARRIER RH
1) Install the filter to the cam carrier RH.
NOTE:
Use a new filter.
Filter insert position:
Cam carrier RH end face 0[+0/-0.5] mm ([+0/-0.0197] in) position
2) Set the intake camshaft RH and the exhaust camshaft RH to the cam carrier RH.
NOTE:
Apply engine oil to the journals of cam carrier RH before setting the intake camshaft RH and exhaust camshaft RH.
3) Install the front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH.
(1) Apply liquid gasket to the mating surface of front camshaft cap RH, intake rear camshaft cap RH and exhaust rear camshaft cap RH as shown in the figure.
CAUTION:
^ Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure.
^ Do not apply liquid gasket excessively to the intake center camshaft cap RH and exhaust center camshaft cap RH.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent
Liquid gasket applying diameter:
Mating surfaces other than range A
1±0.5 mm (0.0394±0.0197 in)
Mating surfaces of range A
2±0.5 mm (0.0787±0.0197 in)
(2) Apply engine oil to the journals of each camshaft cap before setting the camshaft cap.
(3) Tighten the bolts which secure front camshaft cap RH, intake center camshaft cap RH, intake rear camshaft cap RH, exhaust center camshaft cap RH and exhaust rear camshaft cap RH in numerical order as shown in the figure.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
CAM CARRIER LH
1) Install the filter to the cam carrier LH.
NOTE:
Use a new filter.
Filter insert position:
Cam carrier LH end face 0[+0/-0.5] mm ([+0/-0.0197] in) position
2) Set the intake camshaft LH and the exhaust camshaft LH to the cam carrier LH.
NOTE:
Apply engine oil to the journals of cam carrier LH before setting the intake camshaft LH and exhaust camshaft LH.
3) Install the front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH.
(1) Apply liquid gasket to the mating surface of front camshaft cap LH, intake rear camshaft cap LH and exhaust rear camshaft cap LH as shown in the figure.
CAUTION:
^ Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure.
^ Do not apply liquid gasket excessively to the intake center camshaft cap LH and exhaust center camshaft cap LH.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent
Liquid gasket applying diameter:
Mating surfaces other than range A
1±0.5 mm (0.0394±0.0197 in)
Mating surfaces of range A
2±0.5 mm (0.0787±0.0197 in)
(2) Apply engine oil to the journals of each camshaft cap before setting the camshaft cap.
(3) Tighten the bolts which secure front camshaft cap LH, intake center camshaft cap LH, intake rear camshaft cap LH, exhaust center camshaft cap LH and exhaust rear camshaft cap LH in numerical order as shown in the figure.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
INSPECTION
1) Visually check the cam carrier filter, and if clogging is found, replace with a new part.
2) Check the camshaft journals for damage and wear. Replace the camshaft if faulty.
3) Check the cam face condition of camshaft, and remove the minor faults by grinding with oil stone. Replace the camshaft if uneven wear is found.
4) Using a dial gauge, check the camshaft bend. If it exceeds the limit, replace the camshaft.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Camshaft bend limit:
0.020 mm (0.00079 in)
5) Check the cam lobe height "H" and cam base circle diameter "A" of camshaft using micrometer. If it is not within the standard, replace the camshaft.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Cam lobe height H:
Standard
Intake
40.89 - 40.99 mm (1.610 - 1.614 in)
Exhaust
40.15 - 40.25 mm (1.581 - 1.585 in)
Cam base circle diameter A:
Standard
34.0 mm (1.339 in)
6) Check the camshaft journal outer diameter using micrometer. If it is not within the standard, check the oil clearance. Refer to step 7) for inspection procedure of oil clearance.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
Camshaft journal O.D.:
Standard
25.946 - 25.963 mm (1.0215 - 1.0222 in)
7) Check the oil clearance of camshaft journals using plastigauge.
NOTE:
Measurement should be performed at a temperature of 20°C (68°F).
(1) Remove the liquid gasket from cam carrier and front camshaft cap, intake rear camshaft cap and exhaust rear camshaft cap.
(2) Clean each camshaft cap and cam carrier journals.
(3) Set the camshaft to the cam carrier.
(4) Place a plastigauge across the camshaft journals of each camshaft and set the camshaft caps.
(5) Tighten the bolts which secure front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap in numerical order as shown in the figure.
Tightening torque:
18 Nm (1.8 kgf-m, 13.3 ft-lb)
(6) Loosen the bolts (front camshaft cap, intake center camshaft cap, intake rear camshaft cap, exhaust center camshaft cap and exhaust rear camshaft cap) equally, a little at a time in numerical sequence as shown in the figure, and remove the camshaft cap.
(7) Measure the widest point of the plastigauge on each journal. If it is not within the standard, replace the camshaft. If necessary, replace each camshaft cap and cam carrier as a set.
Oil clearance of camshaft journals:
Standard
0.037 - 0.072 mm (0.0015 - 0.0028 in)
(8) Completely remove the plastigauge.
8) Using a dial gauge, check the thrust clearance. If it is not within the standard or if uneven wear is found, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Set the dial gauge at end surface of camshaft.
Camshaft thrust clearance:
Standard
0.068 - 0.116 mm (0.0027 - 0.0047 in)
