Removal [10/2015 - ]: Procedure

Refer to REMOVAL [10/2015 - 11/2017] , or refer to REMOVAL [11/2017 - ]

Refer to REMOVAL [10/2015 - ]

Refer to PROCEDURE - Step 1

1. Slide the clip and disconnect the No. 3 ventilation hose from the cylinder head cover sub-assembly.

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1. Slide the clip and disconnect the No. 2 ventilation hose from the cylinder head cover sub-assembly.

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Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 2

1. Disengage the clamp and disconnect the No. 3 ventilation hose from the engine wire

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2. Disconnect the air fuel ratio sensor connector.
3. Remove the bolt and disconnect the engine wire from the cylinder head cover sub-assembly.

1. Slide the 4 clips and disconnect the No. 1 turbo water by-pass hose, No. 2 turbo water by-pass hose, No. 3 turbo water by-pass hose and No. 4 turbo water by-pass hose.

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   *1	No. 1 Turbo Water By-pass Hose
   *2	No. 2 Turbo Water By-pass Hose
   *3	No. 3 Turbo Water By-pass Hose
   *4	No. 4 Turbo Water By-pass Hose
   *5	No. 1 Turbo Water Pipe

2. Remove the 3 bolts and No. 1 turbo water pipe.

Refer to PROCEDURE - Step 4

See step  11

See step  12

1. Turn the crankshaft until the timing mark (groove) of the crankshaft pulley assembly and the timing mark "0" of the timing chain cover assembly are aligned.

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   *a	Paint Mark
   *b	Timing Mark (Groove)
   *c	Timing Mark "0"

2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly is positioned as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing mark (groove) as shown in the illustration.
3. Place paint marks on the chain sub-assembly in alignment with the timing mark (groove) on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

See step  19

1. Turn the crankshaft approximately 15° clockwise.

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   *a	Approximately 15°

2. Turn the crankshaft approximately 15° counterclockwise.

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   *a	Approximately 15°

3. Align the holes of the stopper plate and No. 1 chain tensioner assembly, and insert a pin into the stopper plate hole to lock the No. 1 chain tensioner assembly.

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   *a	Stopper Plate
   *b	Pin

4. Turn the crankshaft approximately 15° clockwise.

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   *a	Approximately 15°

5. Remove the bolt, nut, No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

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   NOTE:

   Be careful not to drop the gasket into the timing chain cover assembly.

6. Turn the crankshaft approximately 15° counterclockwise.

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   *a	Approximately 15°

See step  22

Refer to PROCEDURE - Step 3

1. Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear bolt from the camshaft.

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   *a	Hold
   	Turn

   NOTE:

   Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

1. Remove the 11 bolts in several steps in the order shown in the illustration.
   Fig 1: Camshaft Bearing Cap Bolts Loosening Sequence

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2. Remove the 10 bolts in the several steps in the order shown in the illustration.
   Fig 2: Camshaft Bearing Cap Bolts Loosening Sequence

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   *1	No. 1 Camshaft Bearing Cap
   *2	No. 2 Camshaft Bearing Cap
   *3	No. 3 Camshaft Bearing Cap
   *4	No. 4 Camshaft Bearing Cap

   NOTE:

   Make sure to loosen the bearing cap bolts evenly while holding the camshaft horizontally.

3. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap from the camshaft housing sub-assembly.

   HINT: 

   Arrange the removed parts in the correct order.

1. Raise the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.

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1. Remove the camshaft timing gear assembly.

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   NOTE:

   Do not disassemble the camshaft timing gear assembly.

1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

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2. Suspend the chain sub-assembly with a string or equivalent as shown in the illustration.

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   NOTE:

   Be careful not to drop the chain sub-assembly into the timing chain cover assembly.

1. Secure the No. 2 camshaft between aluminum plates in a vise.
   1. Using SST, grip the hexagonal portion, and then secure SST and No. 2 camshaft in a vise as shown in the illustration.
      • SST: 09212-31010 

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      *a	Hexagonal Portion

      NOTE:

      • Do not damage the No. 2 camshaft.
      • Never grip areas other than the hexagonal portion, as this may cause damage.
2. Remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

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   NOTE:

   • Be careful not to damage the No. 2 camshaft and camshaft timing exhaust gear assembly.
   • Do not disassemble the camshaft timing exhaust gear assembly.

See step  33

See step  36

See step  37

See step  6