Camshaft/VTC Actuator/Exhaust Camshaft Sprocket Removal, Installation, and Inspection
Camshaft

7. Camshaft Holder Cover - Remove


8. High Pressure Fuel Pump Base - Remove


10. Cam Chain Auto-Tensioner - Lock


1.
Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the cam chain auto-tensioner (B), then insert a 1.2 mm (0.047 in) diameter pin (C) into the holes.

NOTE: If the holes in the lock and the cam chain auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.

2.
Turn the crankshaft clockwise to secure the pin and the TDC on the No. 1 cylinder.

11. Camshaft Holder - Remove

1.
Loosen the rocker arm and the adjusting screws (A).





2.
Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.





3.
Remove cam chain guide B and the camshaft holders (A).

12. Camshaft - Remove


1.
Carefully tip up the intake camshaft on the transmission side of the engine until there is enough slack in the chain to lift the chain off of the VTC actuator's teeth.

2.
Remove the intake camshaft (A), then remove the exhaust camshaft (B) while keeping some tension on the cam chain.

3.
Secure the cam chain (C) to the A/C compressor suction hose with a wire tie to prevent the chain from falling down into the chain case.

VTC Actuator

13. VTC Actuator Lock Pin - Release



1.
Check that the VTC actuator is locked by turning the VTC actuator counterclockwise. If it is not locked, turn the VTC actuator clockwise until it stops, then recheck it. If it is still not locked, replace the VTC actuator.

2.
Seal the retard holes (A) in the No. 1 camshaft journal with tape and a wire tie.





3.
Seal one of the advance holes (A) with tape.





4.
Apply air to the unsealed advance hole to release the lock.

14. VTC Actuator - Remove

1.
Secure the intake camshaft in a vise with wood blocks, then loosen the VTC actuator mounting bolt.

NOTE: After this procedure, remove wood chips that may be stuck to the intake camshaft.





2.
Remove the VTC actuator.

Exhaust Camshaft Sprocket

15. Exhaust Camshaft Sprocket - Remove

1.
Secure the exhaust camshaft in a vise with wood blocks, then loosen the exhaust camshaft sprocket mounting bolt.

NOTE: After this procedure, remove wood chips that may be stuck to the exhaust camshaft.





2.
Remove the exhaust camshaft sprocket.

Exhaust Camshaft Sprocket

1. Exhaust Camshaft Sprocket - Install


1.
Install the exhaust camshaft sprocket.

2.
Apply new engine oil to the threads of the exhaust camshaft sprocket mounting bolts, then loosely install them.





3.
Secure the exhaust camshaft in a vise with wood blocks, then tighten the exhaust camshaft sprocket mounting bolt.

NOTE: After this procedure, remove wood chips that may be stuck to the exhaust camshaft.

Specified Torque:
73 N·m (7.4 kgf·m, 54 lbf·ft)

VTC Actuator

2. VTC Actuator - Install


1.
Install the VTC actuator.

NOTE: Install the VTC actuator while in the unlocked position.

2.
Apply new engine oil to the threads of the VTC actuator mounting bolts, then loosely install them.






3.
Secure the intake camshaft in a vise with wood blocks, then tighten the VTC actuator mounting bolt.

NOTE: After this procedure, remove wood chips that may be stuck to the intake camshaft.

Specified Torque:
115 N·m (11.7 kgf·m, 85 lbf·ft)

4.
Turn the VTC actuator clockwise until you hear it click. Make sure to lock the VTC actuator by turning it.

Camshaft

3. Camshaft - Install


1.
Remove the wire tie while keeping light tension on the cam chain.

2.
Slide the exhaust camshaft (A) and the intake camshaft (B) in at an angle to allow the cam chain to slip over the teeth.






3.
Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

4.
Apply new engine oil to the camshaft journals and lobes on both cams.

4. Camshaft Holder - Install


1.
Apply new engine oil to the threads of the camshaft holder bolts.

2.
Set the camshaft holders (A) and cam chain guide B in place.





3.
Tighten the bolts to the specified torque.

Specified Torque:
13 N·m (1.3 kgf·m, 10 lbf·ft)

5. Rocker Shaft Bolt - Tighten

NOTE: If the rocker arm assembly is disassembled, tighten the rocker shaft bolts.


6. Cam Chain Auto-Tensioner - Unlock


7. Chain Case Cover - Install


1.
Apply liquid gasket to the chain case mating surface of the chain case cover and to the inside edge of the threaded bolt holes.

2.
Install the chain case cover.

9. High Pressure Fuel Pump Base - Install


1.
Apply liquid gasket to the cylinder head mating surface of the high pressure fuel pump base and to the inside edge of the threaded bolt holes.

2.
Install the high pressure fuel pump base.

10. Camshaft Holder Cover - Install


1.
Apply liquid gasket to the cylinder head mating surface of the camshaft holder cover and to the inside edge of the threaded bolt holes.

2.
Install the camshaft holder cover.

15. Fuel Leak (Low Pressure) - Check

1.
Turn the vehicle to the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel rail will be pressurized. Repeat this two or three times, then check for fuel leakage.

VTC Actuator

1. Intake Camshaft - Remove


2. VTC Actuator - Inspection



1.
Check that the VTC actuator is locked by turning the VTC actuator counterclockwise. If it is not locked, turn the VTC actuator clockwise until it stops, then recheck it. If it is still not locked, replace the VTC actuator.

2.
Seal the retard holes (A) in the No. 1 camshaft journal with tape and a wire tie.





3.
Seal one of the advance holes (A) with tape.





4.
Apply air to the unsealed advance hole to release the lock.






5.
Check that the VTC actuator moves smoothly. If the VTC actuator does not move smoothly, replace the VTC actuator.

6.
Remove the wire tie, the tape, and the adhesive residue from the camshaft journal.

3. All Removed Parts - Install

1.
Install the parts in the reverse order of removal.

Camshaft

1. Camshaft - Remove


2. VTC Actuator - Remove


3. Exhaust Camshaft Sprocket - Remove


6. Camshaft - Inspect


1.
Put the rocker shaft holders, the camshaft, and the camshaft holders on the cylinder head, then tighten the bolts, in sequence, to the specified torque.

Specified Torque:
13 N·m (1.3 kgf·m, 10 lbf·ft)

2.
Seat the camshaft by pushing it away from the camshaft pulley end of the cylinder head.






3.
Zero the dial indicator against the end of the camshaft, then push the camshaft back and forth, and read the end play. If the end play is beyond the service limit, replace the cylinder head and recheck. If it is still beyond the service limit, replace the camshaft.

Camshaft End Play
Intake:
Standard (New):
0.05?0.20 mm (0.0020?0.0079 in)
Service Limit:
0.40 mm (0.0157 in)
Exhaust:
Standard (New):
0.05?0.15 mm (0.0020?0.0059 in)
Service Limit:
0.40 mm (0.0157 in)

4.
Loosen the camshaft holder bolts two turns at a time, in a crisscross pattern. Then remove the camshaft holders from the cylinder head.

5.
Lift the camshafts out of the cylinder head, and wipe them clean, then inspect the lift ramps. Replace the camshaft if any lobes are pitted, scored, or excessively worn.

6.
Clean the camshaft journal surfaces in the cylinder head, then set the camshafts back in place. Place a plastigage strip across each journal.

7.
Install the camshaft holders, then tighten the bolts to the specified torque as shown in step 1.





8.
Remove the camshaft holders. Measure the widest portion of plastigage on each journal:

If the camshaft-to-holder clearance is within the service limits, go to step 10.
If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has been replaced, replace the cylinder head.
If the camshaft-to-holder clearance is beyond the service limit, and the camshaft has not been replaced, go to step 9.

Camshaft-to-Holder Oil Clearance
Standard (New):
No. 1 Journal:
0.030?0.069 mm (0.00118?0.00272 in)
Service Limit:
0.150 mm (0.00591 in)
No. 2, No. 3, No. 4, No. 5, and No. 6 Journals:
0.060?0.099 mm (0.00236?0.00390 in)
Service Limit:
0.150 mm (0.00591 in)





9.
Check the total runout with the camshaft supported on V-blocks:

If the total runout of the camshaft is within the standard, replace the cylinder head.
If the total runout is beyond the standard, replace the camshaft and recheck the camshaft-to-holder oil clearance. If the oil clearance is still beyond the standard, replace the cylinder head.

Camshaft Total Runout
Standard (New):
0.03 mm (0.0012 in) max.





10.
Measure cam lobe height.

Cam Lobe Height Standard (New):
 
INTAKE
EXHAUST
PRI
33.858 mm (1.33299 in)
34.340 mm (1.35197 in)
MID
35.252 mm (1.38787 in)
SEC
33.858 mm (1.33299 in)

PRI: Primary
MID: Mid
SEC: Secondary
C/C: Cam Chain
 

7. All Removed Parts - Install

1.
Install the parts in the reverse order of removal.