41. Intake Camshaft and Valve Lifter Installation

Intake Camshaft and Valve Lifter Installation

Note:
* Keep the lash adjuster free of dirt and foreign matter.
* Only use clean engine oil.

1. Install the valve lash adjuster assembly.
2. Place the lash adjuster into a container filled with engine oil.

Note: Install the lash adjuster to the same place it was removed from.

3. Install the lash adjusters.
4. Install the valve rocker arm subassembly
5. Apply engine oil to the lash adjuster tip and valve stem cap end.




6. Make sure that the valve rocker arms (1) are installed properly.
7. Clean both surfaces of the bearings.
8. Install the 2 camshaft bearings.

Note: Position the bearings to the center of the bearing cap.

9. Using vernier calipers, measure the distance between the bearing cap edge and the camshaft bearing edge.

Dimension: 0.7 mm (0.0276 in) or less




10. Install the oil control valve filter (1).
11. Clean both surfaces of the bearings.
12. Install the 2 camshaft bearings.





Note: Position the bearings to the center of the bearing cap by measuring dimension A.

13. Using vernier calipers, measure the distance between the bearing cap edge and the camshaft bearing edge.

Dimension A: 1.05 to 1.75 mm (0.041 to 0.069 in)

14. Clean the camshaft journals.
15. Apply a light coat of engine oil to the camshaft journals, camshaft housings and bearing caps.




16. Install the exhaust camshaft to the camshaft housing.
17. Clean the camshaft journals.
18. Apply a light coat of engine oil to the camshaft journals, camshaft housing.




19. Install the intake camshaft to the camshaft housing.
20. Install the camshaft bearing cap.
21. Apply the engine oil to the bearing caps.





Note: Make sure that the knock pin (5,6) of the camshaft is positioned as shown.

22. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





Caution: Refer to Fastener Caution (Fastener Caution).

23. Install the 10 bolts and tighten in sequence to 16 Nm (12 lb ft).
24. Install the camshaft housing sub-assembly.





Note:
* Remove any oil from the contact surface.
* Install the camshaft housing sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
* Do not start the engine for at least 2 hours after installing.

25. Apply Three Bond 1207B or equivalent, seal packing in a continuous bead (1).

Bead diameter: 3.5 to 4.0 mm (0.138 to 0.158 in)




26. Set the intake and exhaust camshafts.

Note:
* After installing the camshaft housing, make sure that the cam lobes are positioned as shown.
* If any of the bolts are loosened during installation, remove the camshaft housing, clean the installation surfaces, and reapply seal packing.
* If the camshaft housing is removed because any of the bolts are loosened during installation, make sure that the previously applied seal packing does not enter any oil passages.
* After installing the camshaft housing, wipe off any seal packing that seeped out from between the housing and the cylinder head.

27. Install the camshaft housing and 17 bolts and tighten in sequence to 27 Nm (20 lb ft).
28. Install the camshaft timing gear assembly.
29. Check that the knock pin is installed on the camshaft.




30. Put the camshaft timing gear and camshaft together with the straight pin (1) and key groove (2) misaligned.

Note: Do not turn the camshaft timing gear in the retard direction (clockwise).

31. Turn the camshaft timing gear, while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.




32. Measure the clearance between the gear (1) and the camshaft (2).

Clearance: 0.1-0.4 mm (0.004-0.016 in)




33. Install the flange bolt (1) with the camshaft timing gear fixed in place and tighten to 54 Nm (40 lb ft).




34. Check that the camshaft timing gear can move in the retard direction (clockwise) and locks in the most retarded position.
35. Install the camshaft timing exhaust gear assembly.
36. Check that the knock pin is installed on the camshaft.




37. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove (1) and straight pin (2).

Note: Be sure not to turn the camshaft timing exhaust gear in the retard direction (clockwise).

38. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.
39. Check that there is no clearance between the gear flange and the camshaft.




40. Install the flange bolt (1) with the camshaft timing exhaust gear fixed and tighten to 54 Nm (40 lb ft).
41. Make sure that the camshaft timing exhaust gear is locked.