Variable Valve Timing Actuator Removal/Installation

VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [LF]

CAUTION:
- Variable valve timing actuator can not be disassembled because it is a precision unit.

NOTE:
- Intake camshaft sprocket is integrated with the variable valve timing actuator and cannot be disassembled.

1. Remove the battery and battery tray. Removal and Replacement

2. Remove the plug hole plate. Service and Repair

3. Remove the air cleaner. Service and Repair

4. Disconnect the ventilation hose. Service and Repair

5. Remove the front suspension tower bar (joint). ( Service and Repair.)

6. Remove the CMP sensor. Service and Repair

7. Disconnect the oil control valve (OCV) connector.

8. Disconnect the P/S pressure switch connector.

9. Remove the ignition coils. Service and Repair

10. Remove the cylinder head cover. Service and Repair

11. Remove the drive belt. Service and Repair

12. Remove the engine front cover lower blind plug.






13. Remove the engine front cover upper blind plug.






14. Remove the cylinder block lower blind plug.

15. Remove the under cover. Front Suspension - Transverse Member Removal/Installation

16. Install the SST as shown.






17. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position.

18. Loosen the timing chain using the following procedure.
a. Insert a suitable bolt (M6 X 1.0, length 25-35 mm {0.99-1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)






b. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.






c. Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.






d. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.






NOTE:
- The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.






e. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.
NOTE:
- The ratchet has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.





- If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.

19. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.






20. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.

CAUTION:
- Perform the work carefully so that the washer does not drop out.





21. Remove the OCV. Oil Control Valve (OCV) Removal/Installation

22. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.
NOTE:
- The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.





23. Remove the variable valve timing actuator and the camshaft on the intake air side as a single unit.

24. Remove the variable valve timing actuator.
a. Mark the camshaft and variable valve timing actuator as shown in the figure to make sure they are installed in their original position.






b. Secure the camshaft in a vise.

c. Loosen the variable valve timing actuator tightening bolt.

25. Install a new washer.






26. Install the variable valve timing actuator.
a. Secure the camshaft in a vise.

b. Align the marks of the camshaft and variable valve timing actuator.

CAUTION:
- When the variable valve timing actuator is replaced with a new one, mark it in the same location as the old one.

c. Tighten the variable valve timing actuator tightening bolt.

Tightening torque
- 69-75 Nm {7.1-7.6 kgf-m, 50.9-55.3 ft-lbf}

NOTE:
- If the alignment marks on the variable valve timing actuator are not available, refer to the "TIMING CHAIN ASSEMBLY" in the engine overhaul information and perform the sprocket position alignment again.

27. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.






28. With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timing actuator and the camshaft on the intake air side as a single unit.

29. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.






30. Tighten the camshaft cap bolt with the following two steps.






Tightening torque
- (1) Tighten to 5.0-9.0 Nm {51.0-91.7 kgf-cm, 44.3-79.6 in-lbf}
- (2) Tighten to 14.0-17.0 Nm {1.5-1.7 kgf-m, 10.4-12.5 ft-lbf}

31. Install the OCV. Oil Control Valve (OCV) Removal/Installation

32. Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

CAUTION:
- Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer.
- Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.





33. Install the SST to the camshaft as shown in the figure.







34. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25-35mm {0.99-1.3 in}), and apply tension to the timing chain.

35. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position.

36. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.






37. Tighten the exhaust camshaft sprocket bolt.

Tightening torque
- 69-75 Nm {7.1-7.6 kgf-m, 50.9-55.3 ft-lbf}

38. Remove the SST from the camshaft.

39. Remove the SST from the block lower blind plug.

40. Rotate the crankshaft clockwise two turns and inspect the valve timing.

- If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 33.

41. Install the under cover. Front Suspension - Transverse Member Removal/Installation

42. Apply silicone sealant to the engine front cover upper blind plug.

CAUTION:
- Install the engine front cover upper blind plug before the applied silicone sealant starts to harden.

43. Install the engine front cover upper blind plug.






Tightening torque
- 8.0-11.5 Nm {82-117 kgf-cm, 71-101 ft-lbf}

44. Install the cylinder block lower blind plug.






Tightening torque:
- 18-22 Nm {1.9-2.2 kgf-m, 13.3-16.2 ft-lbf}

45. Install the new engine front cover lower blind plug.






Tightening torque:
- 10-14 Nm {102-142 kgf-cm, 89-123 in-lbf}

46. Install the drive belt. Service and Repair

47. Install the cylinder head cover. Service and Repair

48. Install the ignition coils. Service and Repair

49. Connect the OCV connector.

50. Install the CMP sensor. Service and Repair

51. Install the front suspension tower bar (joint). Service and Repair

52. Connect the ventilation hose. Service and Repair

53. Install the air cleaner. Service and Repair

54. Install the plug hole plate. Service and Repair

55. Install the battery and battery tray. Service and Repair