CAMSHAFTEM-63
< REMOVAL AND INSTALLATION > [HR16DE]
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4. Remove the camshaft sprocket (INT):
a. Keeping the camshaft hexagonal part (A) in place using suitable
tool, loosen the bolts for the camshaft sprocket (INT) (2).
CAUTION:
• Do not drop stopper pin.
• Tape (C) the stopper pin (B) so it does not come out.
• Do not subject it to impact by dropping.
• Do not disassemble. [Do not loosen the three bolts (A)].
NOTE:
While removing the camshaft sprocket (INT), if you have taken
out the stopper pin and the lock pin has been rejoined in the
most retarded angle, do the following to restore it.
i. Install the camshaft (INT) and tighten the bolts enough to pre- vent air from leaking out.
CAUTION:
The internal lock pin will ge t damaged, so keep the torque
on the bolts to the minimum required to prevent air from
escaping.
ii. Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position.
iii. Insert the stopper pin.
iv. Remove camshaft sprocket (INT) from the camshaft.
5. Remove camshaft brackets (No. 2 to 5). • Loosen bolts in several steps in the reverse order as shown.
NOTE:
The camshaft bracket (No. 1) has been already removed.
6. Remove camshaft (EXH).
7. Remove camshaft (INT).
8. Remove valve lifter (if necessary). • Identify installation positions, and store lifters without mixing them up.
9. Remove the generator and bracket. Refer to CHG-29, "
Exploded View"
(1) Camshaft (INT)
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PBIC3691E
(A) : EXH side
(B) : INT side
: Engine front
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CAMSHAFTEM-65
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a. Put the matching marks (A) on a line extending from the knock
pin position of camshaft (EXH) (1) front surface.
• Put the marks on the visible position with the camshaftsprocket installed as shown.
b. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (EXH) (2) as shown.
• Put the marks on the visible position with it installed to the
camshaft.
6. Install camshaft.
• Note that the camshafts (INT and EXH) have different shapesat the rear.
• Install camshafts to the cylinder head so that knock pins (A) on front end are positioned as shown.
NOTE:
Though camshaft does not stop at the portion as shown for the
placement of cam nose, it is generally accepted camshaft is
placed for the same direction as shown.
7. Install camshaft brackets (2 to 5) and (A to D).
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(1) : Camshaft (EXH)
(2) : Camshaft (INT)
(A) : Identification mark
Identification Color M1 (A)
Camshaft (EXH) Yellow - Green x 2
Camshaft (INT) White
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(1) : Camshaft (EXH)
(2) : Camshaft (INT) : Upper side
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(A) : EXH side (2 to 5)
(B) : INT side (A to D): Engine front
PBIC3703E
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CAMSHAFT
8. Tighten bolts of camshaft brackets in the following steps, in
numerical order as shown.
a. Tighten No. 9 to 11 in numerical order.
b. Tighten No. 1 to 8 in numerical order.
c. Tighten all bolts in numerical order.
d. Tighten all bolts in numerical order.
9. Install the camshaft sprocket (INT /EXH) to the camshaft (INT/EXH):
a. Refer to the matching mark (A) added in step 4. Securely align the knock pin and the pin hole, and then install them.
NOTE:
The intake side is shown as an example.
10. Tighten the camshaft sprocket bolt (INT/EXH). CAUTION:
Hold the camshaft hexagonal part (A), using a suitable tool
to secure the camshaft.
11. Align the matching mark (peripheral groove) (A/C) and the pink link (B) on the timing chain.
• If the positions of knock pin and pin groove are not aligned,move the camshaft (EXH) slightly to correct these positions.
(A) : EXH side
(B) : INT side
: Engine front
Camshaft bracket bolts : 1.96 N·m (0.20 kg-m, 17 in-lb)
Camshaft bracket bolts : 1.96 N·m (0.20 kg-m, 17 in-lb)
Camshaft bracket bolts : 5.88 N·m (0.60 kg-m, 52 in-lb)
Camshaft bracket bolts : 10.4 N·m (1.1 kg-m, 8 ft-lb)PBIC3686E
PBIC3700E
(1) : Camshaft sprocket (INT)
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(1) : Timing chain
(2) : Camshaft sprocket (EXH)
(3) : Camshaft sprocket (INT)
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CAMSHAFT
• Before starting engine, check oil/fluid levels, including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-11, "
Fluids and Lubricants".
• Use procedure below to check for fuel leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks
at connection points.
• Start engine. With engine speed increased, che ck again for fuel leaks at connection points.
• Run engine to check for unusual noise and vibration. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and 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 make sure there is no leak s of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- ified level, if necessary.
• Summary of the inspection items:
*Power steering fluid, brake fluid, etc.
InspectionINFOID:0000000012431722
INSPECTION AFTER REMOVAL
Oil Filter
• Check that there is no foreign material on the oil filter (1) and check it for clogging.
• Check the oil filter for damage.
• If there is some damage, replace the oil filter, the plug, and the washer as a set.
CAUTION:
Do not reuse the washer.
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour- nals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft
sprocket) because it has a differe nt diameter from the other
four locations.
2. Set a suitable tool vertically to No. 3 journal.
3. Turn camshaft to one direction, and measure the camshaft runout using suitable tool. (Total indicator reading)
Item Before starting engine Engine runningAfter engine stopped
Engine coolant LevelLeaks Level
Engine oil LevelLeaks Level
Transmission/
transaxle fluid CVT Models
LeaksLevel/Leaks Leaks
M/T Models Level/Leaks LeaksLevel/Leaks
Other oils and fluids* LevelLeaks Level
Fuel LeaksLeaksLeaks
Exhaust gas —Leaks —
PBIC3693E
PBIC2499E
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CAMSHAFTEM-71
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• Measure the outer diameter of valve lifter using suitable tool (A).
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head using suit-
able tool (A).
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
• If out of the standard, referring to the each standard of
valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 or P 0014 is detected in self-diagnostic results of CON-
SULT and it is directed according to insp ection procedure of EC section. Refer to EC-168, "
Diagnosis
Procedure" (P0011) or EC-172, "Diagnosis Procedure" (P0014).
• Check when engine is cold so as to pr event burns from the splashing engine oil.
NOTE:
This section provides the inspection method of oil passage of cam sprocket on the intake side. For oil passage
on the exhaust side, the inspection proc edure must be changed as instructed below:
1. Check engine oil level. Refer to LU-7, "
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-137, "
Work Procedure".
b. Remove intake manifold. Refer to EM-28, "
Removal and Installation".
Standard : Refer to
EM-117, "
Camshaft".
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Standard : Refer to EM-117, "Camshaft".
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Standard : Refer to EM-117, "Camshaft".
· Step 3 : Remove exhaust valve timing control solenoid valve. Refer to EM-60, "Exploded View".
· Step 4 : Crank engine, and then check that engine oil comes out from exhaust valve timing control solenoid
valve hole (A). End crank after checking.
·Step 5 Perform the following inspection if engine oil does not come out from exhaust valve timing control
solenoid valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to
EM-60, "
Exploded View".
• Clean oil groove between oil strainer and exhaust valve timing control solenoid valve. Refer to
EM-60, "
Exploded View".
·Step 6 : Remove components between exhaust valve timing control solenoid valve and camshaft sprocket
(EXH), and then check each oil groove for clogging.
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EM-72
< REMOVAL AND INSTALLATION >[HR16DE]
CAMSHAFT
c. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to
EM-60, "
Exploded View".
4. Crank engine, and then check that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank
after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
• Prevent splashing by using a shop cloth to prevent injuryfrom splashing engine oil and so as to prevent engine oil contamination.
• Use a shop cloth to prevent engine oil from bein g splashed to engine and vehicle. Especially be
careful not to spill engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe
engine oil off immediatel y 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. Refer to LU-10, "
Removal and Installation".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-5,
"Engine Lubrication System".
6. Remove components between intake valve timing c ontrol solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-5, "
Engine Lubrication System".
7. After inspection, installation of components is in the reverse order of removal
(1) : Plug
:Engine front
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OIL SEALEM-73
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OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and InstallationINFOID:0000000012431723
REMOVAL
1. Remove camshafts. Refer to
EM-60, "Removal and Installation".
2. Remove valve lifters. Refer to EM-60, "
Removal and Installation".
3. Rotate crankshaft, and set piston with valve oil seal to be removed to TDC. This will prevent the valve from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet, valve spring retainer, and valve spring using Tools.
CAUTION:
• Do not damage valve lifter holes.
• Install Tool (A) in the center of valve spring retainer topress it.
5. Remove valve spring retainer, valve spring and valve spring seat. Refer to EM-78, "
Disassembly and
Assembly".
6. Remove valve oil seal with Tool (A).
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip. Tool number (A) : KV1016200 (J-26336-A)
(B) : KV10109220 ( — )
(C) : KV10115900 (J-26336-20)
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(1) : Valve spring retainer
Tool number (A) : KV10115900 (J-26336-20)
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Tool number (A) : KV10107902 (J-38959)
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< REMOVAL AND INSTALLATION >[HR16DE]
OIL SEAL
2. Press in valve oil seal to the height “H” shown with Tool (A).
3. Installation of the remaining components is in the reverse order of removal.
FRONT OIL SEAL
FRONT OIL SEAL : Remo
val and InstallationINFOID:0000000012431724
REMOVAL
1. Remove front fender protector (RH). Refer to EXT-38, "Removal and Installation".
2. Remove drive belt. Refer to EM-16, "
Removal and Installation".
3. Remove crankshaft pulley. Refer to EM-51, "
Exploded View".
4. Remove front oil seal using suitable tool. CAUTION:
Be careful not to damage front cover and crankshaft.
5. Installation of the remaining components is in the reverse order of removal.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown.
• Press-fit front oil seal using a suitable drift.CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.
3. Installation of the remaining components is in the reverse order of removal.
REAR OIL SEAL
REAR OIL SEAL : Removal and InstallationINFOID:0000000012431725
REMOVAL
1. Remove engine and transaxle assembly. Refer to TM-24, "Removal and Installation" (M/T models) and
TM-259, "
Removal and Installation" (CVT models).
2. Remove clutch cover and clutch disk (M/T models). Refer to CL-19, "
Removal and Installation".
3. Remove flywheel (M/T models) or drive plate (CVT models). Refer to EM-93, "
Exploded View".
4. Remove rear oil seal using suitable tool. Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)
Tool number (A) : KV10115600 (J-38958)
PBIC3211J
(A) : Dust seal lip
(B) : Oil seal lip
: Engine outside
: Engine inside
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