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Disassembly And Assembly




CAMSHAFT

Disassembly and Assembly


DISASSEMBLY







CAUTION:
Never loosen adjusting bolts (A) and mounting bolts (black color) (B) of VVEL ladder assembly. If loosened, the stroke of cam lift becomes out of adjustment. In such case, replacement of VVEL ladder assembly and cylinder head assembly is required.
NOTE:
VVEL ladder assembly cannot be replaced as a single part, because it is machined together with cylinder head assembly.
1.Remove rocker covers (bank 1 and bank 2). Exploded View.
2.Remove VVEL actuator sub assembly as per the following:

CAUTION:
VVEL actuator sub assembly and VVEL control shaft position sensor are not reusable. Never remove them unless they are required.
a.Remove VVEL control shaft position sensor.





b.Fix two flat areas (C) of control shaft with a wrench to remove mounting bolts of control shaft.






CAUTION:
- During the operation, never allow a wrench to interfere with other parts.
- Fix control shaft to prevent the interference of the stopper surface.
c.Remove VVEL actuator sub assembly.





- Loosen mounting bolts in the reverse order as shown in the figure.






CAUTION:
- When removing, prepare wastes because oil spills.
- When installing, be careful with VVEL actuator sub assembly (bank 1) mounting bolt No. 4 because its length is different.
d.Remove actuator bracket (rear).





- Loosen mounting bolts in the reverse order as shown in the figure.





3.Remove front cover, camshaft sprockets, and timing chains. Exploded View.
4.Remove VVEL ladder assembly.





- Loosen mounting bolts (gold color) in the reverse order as shown in the figure.






CAUTION:
- Never loosen adjusting bolts and mounting bolts (black color).
- When removing VVEL ladder assembly, hold the drive shaft from below so as not to drop it.
5.Remove camshaft (EXH).
6.Remove valve lifter, if necessary.
- Identify installation positions, and store them without mixing them up.

ASSEMBLY

1.Install valve lifter.
- Install it in the original position.
2.Install camshaft (EXH).





- Distinction between camshaft (EXH) is performed with the identification mark.





3.Install VVEL ladder assembly as per the following:





a.Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the cylinder head as shown in the figure.





Use Genuine RTV Silicone Sealant or an equivalent. Recommended Chemical Products And Sealants.





b.Tighten mounting bolts in the following step, in numerical order as shown.





i.Tighten bolts in numerical order as shown.







ii.Tighten bolts in numerical order as shown.







iii.Tighten bolts in numerical order as shown.







4.Install camshaft sprockets and timing chains. Exploded View.
5.Install actuator bracket (rear) as per the following:





a.Refer to the figure to replace new dowel pins (2), if removed.










b.Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the actuator bracket (rear) as shown in the figure.





Use Genuine RTV Silicone Sealant or an equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Never apply gasket to the oil passage.





c.Tighten mounting bolts in the following steps, in numerical order as shown.





i.Tighten bolts in numerical order as shown.







ii.Tighten bolts in numerical order as shown.







iii.Tighten bolts in numerical order as shown.







6.Install new VVEL actuator sub assembly as per the following:

CAUTION:
Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one-on-one basis, replace them as a set.
NOTE:





- VVEL actuator arm (B) is factory-fixed at 10 degrees from the small lift with a holding jig (A).
- The holding jig is supplied in the new VVEL actuator sub assembly.

CAUTION:





- Never disassemble VVEL actuator sub assembly. [Never loosen actuator motor mounting bolts (A) shown in the figure]
- Never impact VVEL actuator sub assembly.





a.Move control shaft to the position of small lift stopper.
- The position where a part of the stopper of control shaft contacts VVEL ladder bracket.






CAUTION:
Be careful not to damage the stopper surface.
- If control shaft cannot be moved, set crankshaft in position referring to the information below. (To displace cam nose)









b.Hold two flat areas of control shaft with a wrench, and rotate the control shaft (10 degrees from the stopper) to the large lift side.
(This is for aligning the bolt hole of control shaft and the hole of
VVEL actuator arm.)





NOTE:
The figure shows an example of bank 2.





c.Apply a continuous bead of liquid gasket with tube presser (commercial service tool) to the VVEL actuator sub assembly as shown in the figure.





Use Genuine RTV Silicone Sealant or an equivalent. Recommended Chemical Products And Sealants.

CAUTION:
Never apply gasket to the oil passage.
d.Install new VVEL actuator sub assembly.





- Tighten mounting bolts in the following step, in numerical order as shown.






CAUTION:
- When installing, be careful with VVEL actuator sub assembly (bank 1) mounting bolt No. 4 because its length is different.
- Be sure to check that the VVEL actuator sub assembly is in contact with the cylinder head before tightening the mounting bolts.
e.Remove holding jig.





f.Check that VVEL actuator arm bolt hole is aligned with control shaft tapped hole. If it is not aligned, turn control shaft for alignment.

CAUTION:
Never give an impact to the magnet part. (A)





g.Fix two flat areas (C) of control shaft with a wrench to tighten mounting bolts of control shaft.






CAUTION:
- During the operation, never allow a wrench to interfere with other parts.
- Fix control shaft to prevent the interference of the stopper surface.
7.Install new VVEL control shaft position sensor as per the following:

CAUTION:
Regarding replacement, because VVEL actuator sub assembly and VVEL control shaft position sensor are controlled on a one-on-one basis, replace them as a set.
a.Apply engine oil to O-ring or contact surface of O-ring.





b.Align matching marks (B) of VVEL control shaft position sensor and upper housing.
- Face connector toward matching mark (A).
c.Temporarily tighten bolt.
d.Adjust VVEL control shaft position sensor after setting the engine assembly in the vehicle. Description.

CAUTION:
Be sure to adjust VVEL control shaft position sensor.
e.After adjusting VVEL control shaft position sensor, tighten bolts to the specified torque.
8.Install actuator cover.
9.Inspect the valve clearance. Service and Repair.
10.Install in the reverse order of removal.
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