Disassembly and Assembly
Cam CarrierDISASSEMBLY
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 each 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 each 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 camshaft 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:
^ Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap RH, intake rear camshaft cap RH, exhaust rear camshaft cap RH, and cam carrier RH.
^ 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
2±0.5 mm (0.0787±0.0197 in)
Mating surfaces of range A
3.5±0.5 mm (0.1378±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 camshaft 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:
^ Before applying liquid gasket, degrease the old liquid gasket seal surface of the front camshaft cap LH, intake rear camshaft cap LH, exhaust rear camshaft cap LH, and cam carrier LH.
^ 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 ranges A, B and C
2±0.5 mm (0.0787±0.0197 in)
Mating surfaces of ranges A and C
3.5±0.5 mm (0.1378±0.0197 in)
Mating surfaces of range B
3[+0.5/-0]mm (0.1181[+0.0197/0]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 as shown in the figure, 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).
Camshaft cam lobe overall height H:
Intake
Standard
40.77 - 40.87 mm (1.605 - 1.609 in)
Exhaust
Standard
40.15 - 40.25 mm (1.581 - 1.585 in)
Camshaft 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, replace the camshaft.
NOTE:
^ Measurement should be performed at a temperature of 20°C (68°F).
^ Measure outer diameter of each journal at several points, and read the value of most worn location.
Camshaft journal outer diameter:
Standard
25.946 - 25.963 mm (1.0215 - 1.0222 in)
7) Using a dial gauge, check the thrust clearance of the camshaft. 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)
8) Check the oil clearance on the camshaft using a Plastigauge(R).
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(R) 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 each camshaft cap.
(7) Determine camshaft oil clearance by matching the widest point of Plastigauge(R) on each journal against scale printed on a package of Plastigauge(R). If it is not within the standard, replace each camshaft cap and cam carrier as a set. If necessary replace the camshaft.
Camshaft oil clearance:
Standard
0.037 - 0.072 mm (0.0015 - 0.0028 in)
