Page 417 of 2890
B2M0729
3) Install left-hand belt cover.
4) Install crankshaft pulley.
G2M0711
5) Install pulley bolt by using ST.
ST 499977000 CRANKSHAFT PULLEY WRENCH
6) Install V-belt.
CAUTION:
After installing V-belt, check and adjust V-belt tension.
29
2-3bSERVICE PROCEDURE
2. Timing Belt
Page 418 of 2890
3. Camshaft
A: REMOVAL
1. RELATED PARTS
Remove timing belt, camshaft sprockets and related parts.
2. CAMSHAFT LH
G2M0743
1) Remove camshaft position sensor.
2) Remove ignition coils.
3) Remove rocker cover and gasket.
G2M0744
4) Loosen intake camshaft cap bolts equally, a little at a
time in the numerical sequence shown in figure.
5) Remove camshaft caps and intake camshaft.
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2-3bSERVICE PROCEDURE
3. Camshaft
Page 419 of 2890

G2M0745
6) Loosen exhaust camshaft cap bolts equally, a little at a
time in the numerical sequence shown in figure.
7) Remove camshaft caps and exhaust camshaft.
CAUTION:
Arrange camshaft caps in order so that they can be
installed in their original positions.
8) Similarly, remove right-hand camshafts and related
parts.
G2M0746
B: INSPECTION
1. CAMSHAFT
1) Measure the bend, and repair or replace if necessary.
Limit:
0.020 mm (0.0008 in)
2) Check journal for damage and wear. Replace if faulty.
3) Measure outside diameter of camshaft journal. If the
journal diameter is not as specified, check the oil clear-
ance.
Camshaft journal
Front Center, rear
Standard31.946—31.963 mm
(1.2577—1.2584 in)27.946—27.963 mm
(1.1002—1.1009 in)
G2M0747
4) Measurement of the camshaft journal oil clearance
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head. (Without
installing valve rocker.)
(3) Place plastigauge across each of the camshaft
journals.
(4) Install the bearing caps.
CAUTION:
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge on
each journal.
If the oil clearance exceeds the limit, replace the cam-
shaft. If necessary, replace the camshaft caps and cyl-
inder head as a set.
Standard oil clearance:
0.037—0.072 mm (0.0015—0.0028 in)
Limit:
0.10 mm (0.0039 in)
(7) Completely remove the plastigauge.
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2-3bSERVICE PROCEDURE
3. Camshaft
Page 420 of 2890
G2M0138
5) Check cam face condition; remove minor faults by
grinding with oil stone. Measure the cam height H; replace
if the limit has been exceeded.
Standard:
Intake 41.68—41.78 mm (1.6409—1.6449 in)
Exhaust 41.98—42.08 mm (1.6528—1.6567 in)
Limit:
Intake 41.52 mm (1.6346 in)
Exhaust 41.82 mm (1.6465 in)
G2M0748
6) Measure the thrust clearance of camshaft with dial
gauge. If the clearance exceeds the limit, replace caps and
cylinder head as a set. If necessary replace camshaft.
Standard:
0.040—0.080 mm (0.0016—0.0031 in)
Limit:
0.1 mm (0.004 in)
C: INSTALLATION
1. CAMSHAFT
G2M0750
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 10±0.7 (1.0±0.07, 7.2±0.5)
T2: 20±2 (2.0±0.2, 14.5±1.4)
32
2-3bSERVICE PROCEDURE
3. Camshaft
Page 421 of 2890

B2M0764A
1) Camshaft installation
Apply engine oil to cylinder head at camshaft bearing loca-
tion before installing camshaft. Install camshaft so that
rocker arm is close to or in contact with“base circle”of cam
lobe.
CAUTION:
When camshafts are positioned as shown in figure,
camshafts need to be rotated at a minimum to align
with timing belt during installation.
Right-hand camshaft need not be rotated when set
at position shown in figure.
Left-hand intake camshaft: Rotate 80°clockwise.
Left-hand exhaust camshaft: Rotate 45°counter-clock-
wise.
G2M0752
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating surface.
CAUTION:
Do not apply fluid packing excessively. Failure to do so
may cause excess packing to come out and flow
toward oil seal, resulting in oil leaks.
Fluid packing:
THREE BOND 1215 or equivalent
G2M0753
(2) Apply engine oil to cap bearing surface and install
cap on camshaft as shown by identification mark.
(3) Gradually tighten cap in at least two stages in the
numerical order shown in figure, and then tighten to
specified torque.
(4) Similarly, tighten cap on exhaust side.
After tightening cap, ensure camshaft rotates only
slightly while holding it at“base”circle.
G2M0754
3) Camshaft oil seal installation
Apply grease to new oil seal lips and press onto front end
of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587100 OIL SEAL INSTALLER
ST2 499597000 OIL SEAL GUIDE
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2-3bSERVICE PROCEDURE
3. Camshaft
Page 422 of 2890
G2M0755
4) Rocker cover installation
(1) Install gasket on rocker cover.
Install peripheral gasket and ignition coil gasket.
(2) Apply fluid packing to four front open edges of
peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
(3) Install rocker cover on cylinder head. Ensure gas-
ket is properly positioned during installation.
5) Install ignition coil.
6) Install cam angle sensor.
7) Similarly, install parts on right-hand side.
2. RELATED PARTS
Install timing belt, camshaft sprockets and related parts.
34
2-3bSERVICE PROCEDURE
3. Camshaft
Page 423 of 2890
4. Cylinder Head
A: REMOVAL
1. INTAKE MANIFOLD
1) Remove V-belt.
2) Remove generator, air conditioner compressor and
brackets.
3) Remove hoses and tubes from cylinder block.
4) Disconnect each connector and/or remove connector
bracket.
5) Remove coolant filler tank.
6) Remove intake manifold assembly and gasket.
7) Remove water pipe.
8) Remove crank angle sensor, cam angle sensor and
knock sensor.
9) Remove timing belt, camshaft sprockets and related
parts.
10) Remove rocker cover, camshafts and related parts.
2. CYLINDER HEAD
B2M0770A
35
2-3bSERVICE PROCEDURE
4. Cylinder Head
Page 424 of 2890
G2M0757
1) Remove oil level gauge guide attaching bolt (left-hand
only).
2) Remove cylinder head bolts in numerical sequence
shown in figure.
CAUTION:
Leave bolts
1and4engaged by three or four threads
to prevent cylinder head from falling.
3) While tapping cylinder head with a plastic hammer,
separate it from cylinder block.
Remove bolts
1and4to remove cylinder head.
4) Remove cylinder head gasket.
5) Similarly, remove right-hand cylinder head.
B: DISASSEMBLY
G2M0758
36
2-3bSERVICE PROCEDURE
4. Cylinder Head