Camshaft and Tappet Removal and Installation
Camshaft and Tappet Removal and Installation
Camshaft and Tappet Components
NOTE:
For identification of each cylinder, refer to Precautions for Identification of Cylinder Precautions for Identification of Cylinder.
Removal
1) Remove cylinder head cover. Cylinder Head Cover Removal and Installation
2) Remove accessory drive belt. Removal and Installation
3) Turn crankshaft clockwise with 19 mm wrench, and position piston No.1 at TDC on the compression stroke according to the following procedure.
a) Align the timing mark (1) on the CMP actuator and the timing mark (2) on the exhaust camshaft timing sprocket with the match marks (3) on the camshaft housing No.1.
b) Align notch (1) on the crankshaft pulley with "0" (2) on the timing chain cover.
4) Fix timing chain tensioner according to the following procedure.
a) Remove timing chain cover plug (1) and gasket (2).
b) Insert fore-end of special tool into timing chain tensioner hole (1) through timing chain cover plug hole.
NOTE:
Make sure that special tool is inserted in timing chain tensioner hole, with mirrors or the like.
Special Tool
(A): 09917-16710
c) Fix special tool by tightening special tool fixing bolt (2) to specified torque.
NOTE:
- Use the following bolt for special tool fixing bolt.
- Be sure to tighten specified tool fixing bolt (2) to specified torque. If bolt becomes loose, plunger of timing chain tensioner adjuster may extend, making it difficult to reinstall timing chain properly.
- Do not turn crankshaft after timing chain is fixed with special tool.
Tightening torque
Special tool fixing bolt (a): 8 Nm (0.82 kgf-m, 6.0 lbf-ft)
5) Apply a dab of paint to two timing chain links (2) which meet timing marks (1) on CMP actuator and exhaust camshaft timing sprocket.
6) Remove exhaust camshaft timing sprocket according to the following procedure.
a) Hold hexagonal section of exhaust camshaft using wrench or the like.
b) Loosen exhaust camshaft timing sprocket bolt and remove exhaust camshaft timing sprocket (1).
NOTE:
- Be careful not to drop dowel pin into the space between timing chain cover and cylinder block.
- Do not remove CMP actuator at this procedure.
7) Remove dowel pin from exhaust camshaft.
8) Loosen camshaft housing bolts in numerical order ("1" - "21") evenly and gradually.
9) Remove intake camshaft and exhaust camshaft.
NOTE:
Be careful not to drop timing chain into timing chain cover.
10) Remove camshaft bearings and tappets as necessary.
11) Remove CMP actuator from intake camshaft according to the following procedure if necessary.
a) Hold hexagonal section of intake camshaft using vice.
b) Loosen CMP actuator bolt and remove CMP actuator (1).
NOTE:
The CMP actuator will lose its original performance if it has been disassembled and reassembled.
Do not try to disassemble and repair the CMP actuator. If any faulty condition is found, replace the CMP actuator with a new one.
Installation
Camshaft and Tappet Inspection
1) Install CMP actuator (1) to intake camshaft.
Tightening torque
CMP actuator bolt (a): 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
2) Apply engine oil to contact surface of tappets (arrow), and then Install tappets (1) to cylinder head.
3) Install camshaft bearings according to the following procedure.
NOTE:
The camshaft upper bearing (1) is different in shape from the camshaft lower bearing (2). If these bearings are installed in the wrong (reverse) positions, the VVT system will have operational problems and/or the camshaft could seize up.
Be sure to install the bearings in the specified positions.
a) Fit tab (1) of camshaft bearing to groove (2) of cylinder head or camshaft housing.
b) Press camshaft bearing end (3) until it fully seats in cylinder head or camshaft housing.
c) Apply engine oil to sliding surface (4) of camshaft bearing halves.
NOTE:
If oil is present between the bearing's outside surface and the camshaft housing / cylinder head surface, the bearing could heat up to very high temperature, resulting in seizure.
Be sure to thoroughly wipe off any trace of oil that is present between the bearing's outside surface and the camshaft housing / cylinder head surface.
4) Apply engine oil to sliding surfaces of camshafts, and then install camshafts to cylinder head according to the following procedure.
a) Align the timing chain link (2), which is painted in removal procedure under this section, with timing mark (1) on CMP actuator and install intake camshaft.
b) Install exhaust camshaft and position dowel pin hole (3) of exhaust camshaft downward.
5) Install camshaft housings (1) to proper places distinguished by character (2), number (3) and arrow direction (4) on each camshaft housing.
6) Tighten camshaft housing bolts according to the following procedure.
a) Apply engine oil to bolt thread and seat of camshaft housing bolts.
b) Install camshaft housing No.1 (1).
Install camshaft housing bolts, and tighten them by hand.
c) Tighten camshaft housing bolts in numerical order ("1" - "21") evenly and gradually.
Tightening torque
Camshaft housing bolt* 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
7) Install dowel pin to exhaust camshaft.
NOTE:
Be careful not to drop dowel pin into the space between timing chain cover and cylinder block.
8) Install exhaust camshaft timing sprocket (3) to exhaust camshaft according to the following procedure.
a) Align timing chain link (1), which is painted in "removal" under this section, with timing mark (2) on exhaust camshaft timing sprocket (3), and loop timing chain up over exhaust camshaft timing sprocket.
b) Install exhaust camshaft timing sprocket (3) with timing chain to the exhaust camshaft.
9) Tighten exhaust camshaft timing sprocket bolt (1) using special tool.
Special Tool
(A): 09911-05120
Tightening torque
Exhaust camshaft timing sprocket bolt (a): 60 Nm (6.1 kgf-m, 44.5 lbf-ft)
NOTE:
If the bolt is tightened using the extension special tool until the torque wrench reads the specified torque, the bolt will actually be tightened to a torque much more than the specified torque. This could cause damage to the related components.
Use the formula shown below to determine the correct reading of the torque wrench for its length. Then tighten the bolt until the torque wrench indicates the value thus determined.
Formula for reading value of torque wrench.
M = T X L / (L + "a")
- M: Reading value using extension special tool
- T: Specified torque
- L: Torque wench length
- "a": Dimension of special tool
10) Confirm that painted timing chain links (2) are aligned with timing marks (1) on CMP actuator and exhaust camshaft timing sprocket.
11) Remove special tool from timing chain cover.
12) Install timing chain cover plug (1) with new gasket (2), and tighten it to specified torque.
Tightening torque
Timing chain cover plug (a): 27 Nm (2.8 kgf-m, 20.0 lbf-ft)
13) Check that camshaft and timing chain are installed properly as follows.
a) Check that timing mark (1) on CMP actuator and timing mark (2) on exhaust camshaft timing sprocket are aligned with match marks (3) on camshaft housing No.1.
b) Check that notch (1) on crankshaft pulley is aligned with "0" (2) on timing chain cover.
c) Turn crankshaft clockwise twice and repeat Step a) and b).
NOTE:
- Be sure to turn crankshaft fully twice. If it is once, timing marks on CMP actuator and exhaust camshaft timing sprockets do not meet match marks on camshaft housing No.1.
- After turning crankshaft twice, the painted links of timing chain are not aligned with the timing marks on the CMP actuator and the exhaust timing sprocket, but it is normal.
14) Check valve clearance. Service and Repair
15) Install cylinder head cover. Cylinder Head Cover Removal and Installation