Exploded View
1. Camshaft bracket (No. 2 to 5) 2. Camshaft bracket (No. 1) 3. Camshaft sprocket (EXH) 4. Exhaust valve timing control solenoid valve 5. Oring 6. Camshaft sprocket (INT) 7. Plug (EXH) 8. Washer (EXH) 9. Oil filter (for exhaust valve timing control solenoid valve) 10. Cylinder head 11. Oil filter (for intake valve timing control solenoid valve) 12. Washer (INT) 13. Plug (INT) 14. Oring 15. Intake valve timing control solenoid valve 16. Bracket 17. Valve lifter 18. Camshaft (INT) 19. Camshaft (EXH)
CAUTION:
The rotation direction indicated in the procedure is as viewed from the engine front.
REMOVAL
a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.
(B) : White paint mark (Not used for service)
b. Check that the matching marks on each of the camshaft sprockets are in the position as shown.
(1) : Timing chain
(2) : Camshaft sprocket (EXH)
(3) : Camshaft sprocket (INT)
(A) : Matching mark (Peripheral groove)
(B) : Pink link
(C) : Matching mark (Peripheral groove)
c. Paint matching marks (A) on the timing chain links.
a. Fully push down the lever (B) of chain tensioner (2) from the plug hole, and then insert the stopper pin (A) into the body side hole and secure the lever at the lowest position.
(C) : Front cover has been removed for clarity.
NOTE:
Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example.
CAUTION:
The stopper pin must use a shape that cannot fall in the front cover if dropped.
b. Turn the crankshaft pulley (2) counterclockwise with the camshaft (EXH) (1) held. Apply the tension to the timing chain, and then push the plunger into the inside of chain tensioner.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the camshaft.
c. Pull out the stopper pin (A) of chain tensioner (2) side from plug hole. Lift the lever (B) up to align its hole position with the hole of the body.
(D) : Front cover has been removed for clarity.
d. Insert the stopper pin into the body hole through the lever hole, and then secure the lever at the upper position.
CAUTION:
NOTE:
The timing chain with the front cover installed is not disengaged from the crankshaft sprocket and it is not dropped into the front cover. Therefore, the timing chain tension holding device is not necessary.
9. Turn the camshaft sprocket (INT) to the most advanced position.
CAUTION:
Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position.
Make sure to follow the procedure exactly.
a. Remove camshaft bracket (No. 1) (1).
: Engine front
b. Apply the following air pressure to the No. 1 journal oil hole (A) of camshaft (INT) (1) shown using an air gun.
Air pressure : 300 kPa (3.1 kg/cm2, 44 psi) or more
WARNING:
Eye protection should be worn as needed.
CAUTION:
NOTE:
The air pressure is used to move the lock pin into the disengage position.
c. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternately.
(A) : Air gun
(B) : Rubber nozzle
d. While doing the above, once you hear a click (the sound of the internal lock pin disengaging) from inside the camshaft sprocket (INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position.
(C) : Lock pin engaged
(D) : Most advanced angle
e. Stop applying air pressure and release the camshaft (INT).
f. Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.).
Since it comes out easily, secure it with tape (B) to prevent it from falling out.
NOTE:
The stopper pin shows one example of a hexagonal wrench for 2.5 mm (0.098 in) [length of inserted section: approximately15 mm (0.59 in)].
10. Remove the camshaft sprocket (INT):
a. Keeping the camshaft hexagonal part (A) in place with the wrench, loosen the bolts for the camshaft sprocket (INT) (2).
(1) Camshaft (INT)
CAUTION:
NOTE:
While removing the camshaft sprocket (INT), if you have taken out the stopper pin and the lock pin has been rejoined in the most retarded angle, do the following to restore it.
i. Install the camshaft (INT) and tighten the bolts enough to prevent air from leaking out.
CAUTION:
The internal lock pin will get damaged, so keep the torque on the bolts to the minimum required to prevent air from escaping.
ii. Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position.
iii. Insert the stopper pin.
iv. Remove camshaft sprocket (INT) from the camshaft.
11. Remove camshaft brackets (No. 2 to 5).
(A) : EXH side
(B) : INT side
: Engine front
NOTE:
The camshaft bracket (No. 1) has been already removed.
- Identify installation positions, and store lifters without mixing them up.
INSTALLATION
CAUTION:
Do not reuse Orings or washers.
1. Install oil filter (1) for intake and exhaust valve timing control solenoid valves.
CAUTION:
Do not reuse washers.
NOTE:
The intake side is shown as an example.
2. Install intake and exhaust valve timing control solenoid valves.
3. Install valve lifters.
4. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT):
NOTE:
This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (INT).
a. Put the matching marks (A) on a line extending from the knock pin position of camshaft (INT) (1) front surface.
b. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (INT) (2) as shown.
5. Put a matching mark for positioning the camshaft (EXH) and the camshaft sprocket (EXH):
NOTE:
This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (EXH).
a. Put the matching marks (A) on a line extending from the knock pin position of camshaft (EXH) (1) front surface.
b. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (EXH) (2) as shown.
6. Install camshaft
(1) : Camshaft (EXH)
(2) : Camshaft (INT)
(A) : Identification mark
(1) : Camshaft (EXH)
(2) : Camshaft (INT)
: Upper side
NOTE:
Though camshaft does not stop at the portion as shown for the placement of cam nose, it is generally accepted camshaft is placed for the same direction as shown.
7. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown.
(A) : EXH side
(B) : INT side
: Engine front
8. Tighten bolts of camshaft brackets in the following steps, in numerical order as shown.
(A) : EXH side
(B) : INT side
: Engine front
a. Tighten No. 9 to 11 in numerical order.
Camshaft bracket bolts : 1.96 N*m (2.0 kgm, 14 inlb)
b. Tighten No. 1 to 8 in numerical order.
Camshaft bracket bolts : 1.96 N*m (2.0 kgm, 14 inlb)
c. Tighten all bolts in numerical order.
Camshaft bracket bolts : 5.88 N*m (0.60 kgm, 52 inlb)
d. Tighten all bolts in numerical order.
Camshaft bracket bolts : 10.4 N*m (1.1 kgm, 8 ftlb)
9. Install the camshaft sprocket (INT and EXH) to the camshaft (INT and EXH):
a. Refer to the matching mark (A) added in step 4. Securely align the knock pin and the pin hole, and then install them.
NOTE:
The intake side is shown as an example.
10. Tighten the camshaft sprocket bolt (INT and EXH).
(1) : Camshaft sprocket (EXH)
CAUTION:
Hold the camshaft hexagonal part (A), using a suitable tool to secure the camshaft.
11. Install the camshaft (INT and EXH) to the camshaft sprocket (INT and EXH) (2 and 3) while aligning the matching mark (marked when timing chain is removed) (A) and the pink link (B) of camshaft sprocket (INT and EXH).
(1) : Timing chain
(C) : Matching mark (peripheral groove)
12. Pull out the stopper pin (A), and then apply the tension to the timing chain by rotating the crankshaft pulley clockwise slightly.
(1) : Plunger
(2) : Chain tensioner
(B) : Lever
(C) : Lever hole
(D) : Front cover has been removed for clarity.
a. Remove the stopper pin (A) from the camshaft sprocket (INT).
(B) : Tape
b. Turn the crankshaft pulley (1) slowly clockwise (A) and return the camshaft sprocket (INT) to the most retarded angle position.
(B) : Stopper pin hole
(C) : Most advanced angle
(D) : Lock pin engaged
16. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
17. Check and adjust valve clearance.
18. Installation of the remaining components is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
Item | Before starting engine | Engine running | After engine stopped | |
Engine coolant | Level | Leakage | Level | |
Engine oil | Level | Leakage | Level | |
Transmission/ transaxle fluid | A/T and CVT Models | Leakage | Level/Leakage | Leakage |
M/T Models | Level/Leakage | Leakage | Level/Leakage | |
Other oils and fluids* | Level | Leakage | Level | |
Fuel | Leakage | Leakage | Leakage | |
Exhaust gas | Leakage |
*Power steering fluid, brake fluid, etc.
INSPECTION AFTER REMOVAL
Oil Filter
CAUTION:
Do not reuse the washer.
Camshaft Runout
1. Put Vblock on a precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).
2. If wear exceeds the limit, replace camshaft.
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer (A).
CAMSHAFT BRACKET INNER DIAMETER
CAMSHAFT JOURNAL OIL CLEARANCE
NOTE:
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder head. Replace whole cylinder head assembly.
Camshaft End Play
Measure the camshaft end play on the dial indicator when camshaft is moved forward/backward (in direction to axis).
Standard : 4.000 4.030 mm (0.1574 0.1586 in)
- Dimension "B" for camshaft thrust
Standard : 3.877 3.925 mm (0.1526 0.1545 in)
Camshaft Sprocket Runout
1. Put Vblock on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit : 0.15 mm (0.0059 in)
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head with an inside micrometer (A).
VALVE LIFTER CLEARANCE
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket Oil Groove
CAUTION:
NOTE:
This section provides the inspection method of oil passage of cam sprocket on the intake side. For oil passage on the exhaust side, the inspection procedure must be changed as instructed below:
Step 3 : Remove exhaust valve timing control solenoid valve. Refer to EM56, "Exploded View".
Step 4 : Crank engine, and then check that engine oil comes out from exhaust valve timing control solenoid valve hole (A). End crank after checking.
Step 5 Perform the following inspection if engine oil does not come out from exhaust valve timing control solenoid valve oil hole of the cylinder head.
- Remove oil filter, and then clean it. Refer to EM56, "Exploded View".
- Clean oil groove between oil strainer and exhaust valve timing control solenoid valve. Refer to EM56, "Exploded View".
Step 6 : Remove components between exhaust valve timing control solenoid valve and camshaft sprocket (EXH), and then check each oil groove for clogging.
a. Release the fuel pressure.
b. Remove intake manifold.
c. Disconnect ignition coil and injector harness connectors.
(1) : Plug
:Engine front
WARNING:
CAUTION:
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head.
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging.
7. After inspection, installation of components is in the reverse order of removal
Exploded View 1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH) 4. Camshaft sprocket (INT) 5. Plug 6. Front oil seal 7. Crankshaft pulley 8. Crankshaft pulley b ...
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