Camshaft: Service and Repair
Removal and InstallationEM-67 Exploded View:
REMOVAL
1. Remove front timing chain case, camshaft sprocket and timing chain.
2. Remove fuel sub tube.
3. Loosen camshaft sensor bracket bolts in reverse order as shown in the figure.
<---: Engine front
NOTE:
The order of loosening bolts is the same for bank 1 and bank 2.
4. Remove camshaft brackets.
^ Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for installation.
^ Equally loosen camshaft bracket bolts in several steps in reverse order as shown in the figure.
<---: Engine front
5. Remove camshaft.
6. Remove valve lifter.
^ Identify installation positions, and store them without mixing them up.
7. Remove timing chain tensioners (secondary) (1) from cylinder head.
A: Bank 1
B: Bank 2
^ Remove timing chain tensioners (secondary) with its stopper pin (C) attached.
NOTE:
Stopper pin should be attached when timing chain (secondary) is removed.
INSTALLATION
1. Install timing chain tensioners (secondary) on both sides of cylinder head.
^ Install timing chain tensioners (1) with its stopper pin (C) attached.
Bank 1 side (A): Sliding part facing downward
Bank 2 side (B): Sliding part facing upward
2. Install valve lifter.
^ Install it in the original position.
3. Install camshafts.
^ Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction.
<---: Engine front
^ Install camshaft so that dowel pin (A) on front end face are positioned as shown in the figure. (No. 1 cylinder TDC on its compression stroke)
1: Crankshaft key
NOTE:
Though camshaft does not stop at the portion as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
4. Install camshaft brackets.
A: No. 1
B: No. 2
C: No. 3
D: No. 4
E: Camshaft brackets (bank 1)
F: Exhaust side
G: Intake side
H: Camshaft brackets (bank 2)
I: Intake side
J: Exhaust side
<---: Engine front
^ Remove foreign material completely from camshaft bracket backside and from cylinder head installation face.
^ Install camshaft bracket in original position and direction as shown in figure.
^ Install camshaft brackets (No. 2 to 4) aligning the stamp marks (A) as shown in the figure.
B: Bank 1
C: Bank 2
<---: Engine front
NOTE:
There are no identification marks indicating bank 1 and bank 2 for camshaft bracket (No. 1).
^ Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown on both bank 1 and bank 2.
a: 8.5 mm (0.335 in)
b: 2 mm (0.08 in)
c: Clearance 5 mm (0.20 in)
d: [diameter]2.5 mm (0.098 in)
*: Apply liquid gasket to rear timing chain side
Use Genuine RTV Silicone Sealant or equivalent.
^ Apply liquid gasket to camshaft bracket (No. 1) contact surface on the rear timing chain case backside as shown on both bank 1 and bank 2.
1: Rear timing chain case
a: [diameter]3.9 mm (0.154 in)
Use Genuine RTV Silicone Sealant or equivalent.
CAUTION:
For camshaft bracket (No. 1) near installation position, and install it without disturbing the liquid gasket applied to the surfaces.
5. Tighten camshaft bracket bolts in the following steps, in numerical order as shown in the figure.
<---: Engine front
a. Tighten No. 7 to 10 in numerical order as shown.
Torque: 1.96 Nm (0.20 kg-m, 1 ft-lb)
b. Tighten No. 1 to 6 in numerical order as shown.
Torque: 1.96 Nm (0.20 kg-m, 1 ft-lb)
c. Tighten No. 1 to 10 in numerical order as shown.
Torque: 5.88 Nm (0.60 kg-m, 4 ft-lb)
d. Tighten No. 1 to 10 in numerical order as shown.
Torque: 10.4 Nm (1.1 kg-m, 8 ft-lb)
6. Tighten camshaft sensor bracket bolts in numerical order as shown in the figure.
<---: Engine front
NOTE:
The order of tightening bolts is the same for bank 1 and bank 2.
7. Inspect and adjust the valve clearance. Refer to EM-18, "Inspection and Adjustment". Testing and Inspection
8. Install in the reverse order of removal after this step.
Inspection
INSPECTION AFTER REMOVAL
Camshaft Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on a dial indicator. (Total indicator reading)
Standard and limit: Refer to EM-140, "Camshaft". Service Limits and General Specifications
4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer.
Standard cam height: Refer to EM-140, "Camshaft". Service Limits and General Specifications
(Intake and exhaust)
Cam wear limit: Refer to EM-140, "Camshaft". Service Limits and General Specifications
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).
Standard: Refer to EM-140, "Camshaft". Service Limits and General Specifications
CAMSHAFT BRACKET INNER DIAMETER
^ Tighten camshaft bracket bolt with the specified torque. Refer to "INSTALLATION" for the tightening procedure.
^ Measure inner diameter (A) of camshaft bracket with a bore gauge.
Standard: Refer to EM-140, "Camshaft". Service Limits and General Specifications
CAMSHAFT JOURNAL OIL CLEARANCE
^ (Oil clearance) = (Camshaft bracket inner diameter) - (Camshaft journal diameter).
Standard and limit: Refer to EM-140, "Camshaft". Service Limits and General Specifications
^ If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because there are machined together with cylinder head. Replace whole cylinder head assembly.
Camshaft End Play
^ Install a dial indicator in thrust direction on front end of camshaft. Measure the end play of a dial indicator when camshaft is moved forward/backward (in direction to axis).
Standard and limit: Refer to EM-140, "Camshaft". Service Limits and General Specifications
^ Measure the following parts if out of the limit.
^ Dimension "A" for camshaft No. 1 journal
Standard: 27.500 - 27.548 mm (1.0827 - 1.0846 in)
^ Dimension "B" for cylinder head No. 1 journal bearing
Standard: 27.360 - 27.385 mm (1.0772 - 1.0781 in)
^ Refer to the standards above, and then replace camshaft and/or cylinder head.
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Measure the camshaft sprocket runout with a dial indicator. (Total indicator reading)
Limit: Refer to EM-140, "Camshaft". Service Limits and General Specifications
^ If it exceeds the limit, replace camshaft sprocket.
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
^ If anything above is found, replace valve lifter. Refer to EM-140 "Camshaft". Service Limits and General Specifications
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
^ Measure the outer diameter at 1/2 height of valve lifter with a micrometer (A) since valve lifter is in barrel shape.
Standard (Intake and exhaust): Refer to EM-140, "Camshaft". Service Limits and General Specifications
VALVE LIFTER HOLE DIAMETER
^ Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer.
Standard (Intake and exhaust): Refer to EM-140, "Camshaft". Service Limits and General Specifications
VALVE LIFTER CLEARANCE
^ (Valve lifter clearance) = (Valve lifter hole diameter) - (Valve lifter outer diameter)
Standard (Intake and exhaust): Refer to EM-140, "Camshaft". Service Limits and General Specifications
^ If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
^ Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III and it is directed according to inspection procedure. Refer to EC-100, "Diagnosis Description". P0011
^ Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-6, "Inspection". Testing and Inspection
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking.
a. Release the fuel pressure. Refer to EC-538, "Inspection". Service and Repair
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve.
4. Crank engine, and then check that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank after checking.
1: Valve timing control cover (bank 1)
<---: Engine front
WARNING:
Be careful not to touch rotating parts. (drive belt, idler pulley, and crankshaft pulley, etc.)
CAUTION:
^ Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination.
^ Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
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.
^ Remove oil filter, and then clean it.
^ Clean oil groove between oil strainer and intake valve timing control solenoid valve.
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging.
^ Clean oil groove if necessary.
7. After inspection, install removed parts in the reverse order.
Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
^ Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/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.
^ Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
