11A-CAMSHAFT REMOVAL AND INSTALLATION

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal and Installation (Refer to GROUP 51 - Under Cover ).
Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner ).

			Camshaft removal steps
		1.	Engine upper cover
		•	Ignition coil (Refer to GROUP 16 - Ignition System, Ignition Coil ).
		2.	Rocker cover breather hose connection
		3.	Rocker cover PCV hose connection
		4.	Control wiring harness connection
<<A>>	>>G<<	5.	Rocker cover assembly
		6.	Rocker cover gasket
<<B>>		•	Number 1 cylinder compression top dead center setting (only at removal).
		•	Valve clearance adjustment (Refer to ) (only at installation).
		7.	Service hole bolt
<<C>>		•	Camshaft and camshaft sprocket assembly (exhaust side) removal preparatory operation (only at removal)
<<D>>	>>F<<	8.	Camshaft bearing front cap assembly
	>>E<<	9.	Camshaft bearing
<<E>>	>>D<<	10.	Camshaft bearing oil feeding cap (exhaust side)
<<E>>	>>D<<	11.	Camshaft bearing cap (exhaust side)
<<E>>	>>D<<	12.	Camshaft bearing cap (exhaust side)
<<E>>	>>D<<	13.	Camshaft bearing thrust cap (exhaust side)
<<F>>	>>E<<	14.	Camshaft and camshaft sprocket assembly (exhaust side)
<<G>>	>>B<<	15.	Exhaust V.V.T. sprocket assembly
<<G>>	>>B<<	16.	Camshaft (exhaust side)
	>>E<<	17.	Camshaft bearing
<<E>>	>>D<<	18.	Camshaft bearing oil feeding cap (intake side)
<<E>>	>>D<<	19.	Camshaft bearing cap (intake side)
<<E>>	>>D<<	20.	Camshaft bearing cap (intake side)
<<E>>	>>D<<	21.	Camshaft bearing thrust cap (intake side)
	>>C<<	22.	Camshaft and camshaft sprocket assembly (intake side)
<<G>>	>>B<<	23.	Intake V.V.T. sprocket assembly
<<G>>	>>B<<	24.	Camshaft (intake side)
			Oil control valve removal steps
		1.	Engine upper cover
<<H>>	>>A<<	25.	Oil feeder control valve (OCV) intake
	>>A<<	26.	O-ring
<<H>>	>>A<<	27.	Oil feeder control valve (OCV) exhaust
	>>A<<	28.	O-ring

Required Special Tool:

MB992103: Chain Tension Release Bar

REMOVAL SERVICE POINTS

<<A>> ROCKER COVER ASSEMBLY REMOVAL

Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.

<<B>> NUMBER 1 CYLINDER COMPRESSION TOP DEAD CENTER SETTING

caution

Turn the crankshaft clockwise.

Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the number 1 cylinder to the top dead center of compression. At this time, check that the crankshaft pulley timing mark is in the "T" mark position of the ignition timing indicator of the timing chain case assembly.

2. Put paint marks on both the camshaft sprocket and valve timing chain at the position of camshaft sprocket timing chain mating mark (circular hole).

<<C>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL PREPARATORY OPERATION

1. Insert a precision flat-tipped screwdriver through the service hole of the timing chain case assembly, press up the timing chain tensioner ratchet to unlock, and keep the timing chain tensioner with that state.

note	Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.

caution

When inserting the special tool into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool beyond its insertion guideline.
If unlocking the timing chain tensioner is insufficient, the special tool cannot be inserted to the insertion guideline. Do not insert the special too forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool.

With the timing chain tensioner unlocked, insert special tool MB992103 from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (A in the figure).

note

With the timing chain tensioner unlocked, insert the special tool along the tension side of the valve timing chain, according to the special tool top shape. The special tool can be inserted smoothly to the position where the special tool insertion guideline aligns with the timing chain case assembly top surface (B in the figure), and the spread timing chain tension side guide can be hold (C in the figure).

3. With the special tool inserted up to the insertion guide line, press the special tool against the intake side camshaft sprocket and spread and hold the timing chain tension side guide.

4. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.

caution

The valve timing chain may be bitten by other parts. After sagging the valve timing chain, never rotate the crankshaft.

With the timing chain tension side guide spread, hook the special tool over the hexagon part of the camshaft on the exhaust side, and turn the camshaft clockwise to apply slack to the valve timing chain between the camshaft sprockets.

<<D>> CAMSHAFT BEARING FRONT CAP ASSEMBLY REMOVAL

caution

Be careful not to drop the camshaft bearing.

Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

<<E>> CAMSHAFT BEARING OIL FEEDING CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING THRUST CAP REMOVAL

caution

When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are damaged. Always loosen the mounting bolts in four or five steps.

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<<F>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL

1. Raise slightly the transaxle side of the camshaft and camshaft sprocket assembly (exhaust side) by using the slack of the valve timing chain, and remove from the cam bearing.

2. Remove the valve timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transaxle.

3. Remove special tool MB992103 inserted into the timing chain case assembly inside.

caution

The valve timing chain may be bitten by other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.

After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the valve timing chain with a rope to prevent the valve timing chain from falling into the timing chain case assembly.

<<G>> V.V.T. SPROCKET/CAMSHAFT REMOVAL

Hold the hexagon part of the camshaft with a monkey wrench. Loosen the V.V.T. sprocket mounting bolt and remove the V.V.T. sprocket from the camshaft.

<<H>> OIL FEEDER CONTROL VALVE REMOVAL

caution

After removal of the oil feeder control valve, be careful to prevent dust from getting into the oil passage in the cylinder head.

INSTALLATION SERVICE POINTS

>>A<< O-RING/OIL FEEDER CONTROL VALVE INSTALLATION

caution

When installing the oil feeder control valve, be careful to avoid damage to the O-ring.

Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.

>>B<< CAMSHAFT/V.V.T. SPROCKET INSTALLATION

1. Use a monkey wrench to secure the hexagon part of the camshaft in the same manner as removal.

2. Apply an adequate and minimum amount of engine oil to the positions shown of the camshaft and the V.V.T. sprocket.

3. Install the V.V.T. sprocket to the camshaft.

4. Apply an adequate and minimum amount of engine oil to the V.V.T. sprocket bolt.

5. Tighten the V.V.T. sprocket mounting bolt to the specified torque.

Tightening torque: 59 ± 5 N·m (44 ± 3 ft-lb)

>>C<< CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (INTAKE SIDE) INSTALLATION

1. Align the intake side paint mark of the valve timing chain which was put at removal with the paint mark of the intake side camshaft sprocket, and install the camshaft sprocket to the valve timing chain.

2. Install the camshaft and camshaft sprocket assembly (intake side) to the cylinder head.

>>D<< CAMSHAFT BEARING THRUST CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING OIL FEEDING CAP INSTALLATION

1. Install the camshaft bearing caps to the cylinder head.

note	Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.

2. Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps.

Tightening torque: 12 ± 1 N·m (107 ± 8 in-lb)

>>E<< CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION

caution

Be careful not to drop the camshaft bearing.
When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.

When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap assembly identification mark in the table below. The camshaft bearing identification mark is stamped at the position shown in the figure.

Camshaft bearing front cap assembly		Camshaft bearing identification mark
Identification mark	Journal diameter mm (in)	Camshaft bearing identification mark
1	40.000 - 40.008 (1.5748 - 1.5751)	1
2	40.008 - 40.016 (1.5751 - 1.5754)	2
3	40.016 - 40.024 (1.5754 - 1.5757)	3

2. In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case assembly, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner.

note	Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.

caution

When inserting the special tool into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool beyond its insertion guideline.
If unlocking the timing chain tensioner is insufficient, the special tool cannot be inserted to the insertion guideline. Do not insert the special tool forcibly, follow Step 2 again to unlock the timing chain tensioner and insert the special tool.

note

With the timing chain tensioner unlocked, insert the special tool along the tension side of the valve timing chain, according to the special tool top shape. The special tool can be inserted smoothly to the position where the special tool insertion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.

4. With the special tool inserted up to the insertion guide line, press the special tool against the intake side camshaft sprocket (B in the figure) and spread and hold the timing chain tension side guide (C in the figure).

5. Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.

6. Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the valve timing chain (D in the figure) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the valve timing chain.

caution

When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.

Align the exhaust side paint mark of the valve timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the valve timing chain to the camshaft sprocket.

8. Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.

9. Remove the special tool inserted into the timing chain case assembly inside.

>>F<< CAMSHAFT BEARING FRONT CAP ASSEMBLY INSTALLATION

caution

When the mounting bolts are tightened with the camshaft bearing front cap tilted, the camshaft bearing front cap is damaged. Install the camshaft bearing front cap properly to the cylinder head and camshaft.

Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap mounting bolts to the specified torque in the order shown in the figure (1).

Tightening torque: 17 ± 3 N·m (13 ± 2 ft-lb)

2. Tighten again the camshaft bearing front cap mounting bolts to the specified torque again in the order shown in the figure (2).

Tightening torque: 30 ± 2 N·m (22 ± 1 ft-lb)

3. After the camshaft bearing font cap installation, check that the paint markings of the camshaft sprocket and the timing chain and the timing mark of the crankshaft pulley and the "T" mark position of ignition timing indicator are aligned respectively.

>>G<< ROCKER COVER ASSEMBLY INSTALLATION

1. Remove the sealant from the mating surfaces of rocker cover assembly, cylinder head, and timing chain case assembly, and degrease the surface where the sealant is applied.

caution

After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

To the joints between the cylinder head and timing chain case assembly, apply the sealant with a diameter of 4 mm (0.16 inch) as shown in the figure. Then, install the rocker cover assembly to the cylinder head.

Specified sealant: ThreeBond 1227D or equivalent

note	Install the rocker cover assembly immediately after applying sealant.

3. Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.

Tightening torque: 3.0 ± 1.0 N·m (27 ± 8 in-lb)

4. Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.

Tightening torque: 5.5 ± 0.5 N·m (49 ± 4 in-lb)