Installation

CAUTION: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.





1. Install intake camshaft
a. Apply Multipurpose (Mp) grease to the thrust portion of the camshaft.
b. Place the intake camshaft at 80-115° BTDC of camshaft angle on the cylinder head.

NOTE: The above angle allows the No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.





c. Apply seal packing to the No.1 bearing cap as shown. Seal packing: Part No.08826-00080 or equivalent





d. Install the bearing caps in their proper locations.





e. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
f. Install and uniformly tighten the ten bearing cap bolts in several passes, in the sequence shown.
Torque: 19 Nm (14 ft lb)





g. Apply Mp grease to a new oil seal lip.





h. Using SST 09223-46011, tap in the oil seal.





2. Install exhaust camshaft
a. Set the knock pin of the intake camshaft at 10-45° BTDC of camshaft angle.

NOTE: The above angle allows the No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve liters evenly.





b. Apply Mp grease to the thrust portion of the camshaft.
c. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks on each gear.
d. Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other.

NOTE: There are also assembly reference marks on each gear as shown in the illustration. Do not use these marks.





e. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.

NOTE: It is very important to replace the camshaft in the bearing journals evenly while tightening bearing caps in the subsequent steps.

f. Install the bearing caps in their proper locations.





g. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
h. Install and uniformly tighten the ten bearing cap bolts in several passes. in the sequence shown.
Torque: 19 Nm (14 ft lb)





i. Remove the service bolt (B).
3. Check and adjust valve clearance.
Turn the camshaft and position the cam lobe upward, and check and adjust the valve clearance. Valve clearance (Cold):
Intake:
0.19-0.29 mm (0.007-0.011 in.)
Exhaust:
0.28-0.38 mm (0.011-0.015 in.)
If clearance not within specifications adjust valve clearance.





4. Install semi-circular plugs.
a. Remove any old packing (Formed in Place Gasket (FIPG))material.
b. Apply seal packing to the semi-circular plug grooves. Seal packing:
Part No.08826-00080 or equivalent





c. Install the two semi-circular plugs to the cylinder head.





5. Install cylinder head cover.
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent





c. Install the gasket to the head cover.
d. Install the head cover with the four grommets and nuts. Uniformly tighten the nuts in several passes.
Torque: 23 Nm (17 ft lb)

NOTE: Install the grommets so that their markings are as shown in the illustration.

6. Install the camshaft timing pulley.





7. Install No.3 timing belt cover, install the timing belt cover with the four bolts.
Torque: 7.8 Nm (69 in lb)
8. Install the timing belt.