Section 486 (Engine Mechanical Camshaft): Camshaft: Replacement

1. Remove the 2 screw, 3 clips and engine under cover.

Fig 1: Removing Cylinder Head Cover No. 2

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1. Turn the drive belt tensioner clockwise to relieve tension on the belt, and then remove the belt.
2. Carefully return the tensioner to the unloaded position.

Fig 2: Removing Fan And Generator V Belt

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1. Remove the PS oil pump reservoir and put it aside.
2. Place a wooden block between the jack and engine, and set the jack, then remove the 4 bolts, the 2 nuts and engine mounting insulator RH.
   Fig 3: Placing Wooden Block Between Jack And Engine

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   Fig 4: Removing Engine Mounting Insulator RH

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1. Remove the 5 clamps from the 5 clamp brackets.
2. Disconnect the 4 ignition coil connectors.
   Fig 5: Disconnecting Ignition Coil Connectors

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3. Remove the bolt and nut installing the engine wire.
   Fig 6: Disconnecting Engine Wire

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1. Remove the 4 bolts and 4 ignition coils.

Fig 7: Removing Ignition Coil Assy

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1. Disconnect the ventilation hose from the cylinder head cover.

Fig 8: Disconnecting Ventilation Hose From Cylinder Head Cover

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1. Disconnect the ventilation hose from the cylinder head cover.

Fig 9: Disconnecting Ventilation Hose No. 2

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1. Remove the 9 bolts, 2 seal washers, 2 nuts, 3 clamp brackets and cylinder head cover.

Fig 10: Removing Cylinder Head Cover

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1. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
2. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.

HINT:

If not, turn the crankshaft 1 revolution (360°) and align the marks as above.

Fig 11: Checking Alignment Of Point Marks Of Camshaft Timing Sprocket And VVT Timing Sprocket On Timing Chain Cover

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1. Remove the bolt, nut and V-ribbed belt tensioner.

HINT:

Handle a jack up and down to remove the bolt.

Fig 12: Removing V-Ribbed Belt Tensioner

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1. Set the No. 1 cylinder to the TDC/compression.
2. Place match marks on the timing chain and camshaft timing sprockets.
   Fig 13: Placing Match Marks On Timing Chain And Camshaft Timing Sprockets

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3. Remove the 2 nuts and chain tensioner.
   Fig 14: Removing Chain Tensioner

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4. Fix the camshaft with a wrench and so on, then loosen the camshaft timing gear set bolt.
   NOTE: Be careful not to damage the valve lifter.
   Fig 15: Loosening Camshaft Timing Gear Set Bolt

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5. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the order as shown in the illustration in several passes, and remove the caps.
   Fig 16: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts On No. 2 Camshaft

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6. Remove the camshaft timing gear as shown in the illustration.
   Fig 17: Removing Camshaft Timing Gear

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7. Loosen the camshaft bearing cap bolts on camshaft in the order as shown in the illustration in several passes, and remove the caps.
   Fig 18: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts On Camshaft

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8. Remove the camshaft with holding the timing chain.
   Fig 19: Removing Camshaft With Holding Timing Chain

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9. Tie the timing chain with a string as shown in the illustration.

Fig 20: Tie Timing Chain With String

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1. Check the lock of camshaft timing gear.
   1. Grip the camshaft with a vice, and confirm the camshaft timing gear is locked.
      NOTE: Be careful not to damage the camshaft.
2. Release lock pin.
   1. Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.

      HINT:

      Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.

   2. Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
      Fig 21: Covering Oil Paths Of Cam Journal With Vinyl Tape

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   3. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5 kgf.cm}.
      CAUTION: Cover the patches with shop rag to avoid oil splashing.
      Fig 22: Putting Air Pressure Into Two Broken Paths (Advance Side Path And Retard Side Path)

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   4. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path.

      HINT:

      The lock pin is released, and camshaft timing gear, revolves in the advance direction.

      Fig 23: Weakening Air Pressure Of Timing Retard Path

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   5. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, take out that of timing advance side path.
      CAUTION: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side path. It often causes the breakage of the lock pin.
3. Check smooth revolution
   1. Revolve the camshaft timing gear assembly within the movable range except for the most retarded position several times, and check the smooth revolution.
      CAUTION: Be sure to perform this check by hand, instead of air pressure.
4. Check the lock in the most retarded position.
   1. Confirm that the camshaft timing gear assembly is locked at the most retarded position.

1. Grip the camshaft with a vice, and confirm that it the gear locked.
   CAUTION: Be careful not to damage the camshaft.
2. Cover 4 oil paths of cam journal with vinyl tape as shown in the illustration.

   HINT:

   Two advance side paths are provided in the groove of the camshaft. Plug one of the path with a rubber piece.

3. Break through the tapes of the advance side path and the retard side path on the opposite side of the groove.
   Fig 24: Covering Oil Paths Of Cam Journal With Vinyl Tape

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4. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa {1.5 kgf.cm}.
   CAUTION: Cover the patches with shop rag to avoid oil splashing.
   Fig 25: Putting Air Pressure Into Two Broken Paths (Advance Side Path And The Retard Side Path)

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5. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when weakening the air pressure of the timing retard path.

   HINT:

   The lock pin is released, and camshaft timing gear revolves in the advance direction.

   Fig 26: Decompressing Air Pressure Of Timing Retard Path

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6. When the camshaft timing gear comes to the most advanced position, take out the air pressure of the timing retard side path, and then, takeout that of timing advance side path.
   CAUTION: Camshaft timing gear assembly occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released before retard side paths. It often causes the breakage of the lock pin.
7. Remove the fringe bolt of camshaft timing gear assembly.
   NOTE:

   • Be sure not to remove the other 4 bolts.
   • In case of reusing the camshaft timing gear, release the strait pin locking first, and then install the gear.
   Fig 27: Removing Fringe Bolt Of Camshaft Timing Gear Assembly

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1. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
2. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.
   CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).
3. Check that there is no clearance between the gear's fringe and the camshaft.
4. Tighten the fringe bolt with the camshaft timing gear fixed.

   Torque: 54 N.m (551 kgf.cm 40 ft.lbf) 

   Fig 28: Putting Camshaft Timing Gear Assembly And Camshaft Together With Straight Pin Off Key Groove

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5. Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at the most retarded position.

1. As shown in the illustration, install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing gear.
   Fig 29: Installing Timing Chain On Camshaft Timing Gear

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2. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.

   Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

   Fig 30: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts

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3. Put the camshaft No.2 on the cylinder head with the painted links of the chain aligned with the timing mark on the camshaft timing gear.
   Fig 31: Aligning Painted Links Of Chain With Timing Mark On Camshaft Timing Gear While Putting Camshaft No 2 On Cylinder Head

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4. Tighten the camshaft timing gear set bolt temporarily.
   Fig 32: Tightening Camshaft Timing Gear Set Bolt

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5. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.

   Torque: 13 N.m (133 kgf.cm, 10 ft.lbf) 

6. Install the bearing cap No. 1.

   Torque: 23 N.m (235 kgf.cm, 17 ft.lbf) 

   Fig 33: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts

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7. Fix the camshaft with a wrench and so on, then tighten the camshaft timing gear set bolt.

   Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 

   NOTE: Be careful not damage the valve lifter.
   Fig 34: Tightening Camshaft Timing Gear Set Bolt

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8. Check the match marks on the timing chain and camshaft timing sprockets, and then the alignment of the pulley groove with timing mark of the chain cover as shown in the illustration.
   Fig 35: Checking Match Marks On Timing Chain And Camshaft Timing Sprockets

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9. Install chain tensioner.
   1. Check the O-ring is clean, and set the hook as shown in the illustration.
      Fig 36: Setting Hook

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   2. Apply engine oil to the chain tensioner and install it with the 2 nuts.

      Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

      NOTE: When installing the tensioner, set the hook again if the hook release the plunger.
      Fig 37: Installing Chain Tensioner

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   3. Turn the crankshaft counter clockwise, and disconnect the plunger knock pin from the hook.
      Fig 38: Disconnecting Plunger Knock Pin From Hook

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   4. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.

      HINT:

      If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver so that the hook is released from the knock pin and the plunger springs out.

      Fig 39: Pushing Slipper By Plunger

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1. Install the V-ribbed belt tensioner with the nut and bolt.

   Torque: 

   Nut 29 N.m (296 kgf.cm, 21 ft.lbf) 

   Bolt 69 N.m (704 kgf.cm, 51 ft.lbf) 

   Fig 40: Installing V-Ribbed Belt Tensioner Assy

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1. Remove any old packing (FIPG) material.
2. Apply seal packing to 2 locations as shown in the illustration.

   Seal packing: Part No. 08826-00080 or equivalent 

   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 3 minutes after applying seal packing.
   • Do not put into engine oil 2 hours after installing.
   Fig 41: Applying Seal Packing To Cylinder Block

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3. Install the cylinder head cover and 3 cable brackets with the 9 bolts, 2 seal washers and 2 nuts. Uniformly tighten the bolts and nuts, in the several passes.

   Torque: 

   A 11 N.m (112 kgf.cm, 8 ft.lbf) 

   B 9.0 N in (92 kgf.cm, 80 in..lbf) 

   Fig 42: Installing Cylinder Head Cover

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1. Install the 4 ignition coils with the 4 bolts.

   Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

Fig 43: Installing Ignition Coil Assy

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1. Install the engine wire with the bolt and nut.

   Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

   Fig 44: Installing Engine Wire

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1. Install engine mounting insulator with the 4 bolts and 2 nuts.

   Torque: 52 N.m (530 kgf.cm, 38 ft.lbf) 

   Fig 45: Installing Engine Mounting Insulator Sub-Assy RH

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1. Install the cylinder head cover with the 2 nuts and 2 clips.

   Torque: 7.0 N.m (71 kgf.cm, 62 in..lbf) 

Fig 46: Installing Cylinder Head Cover No. 2

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