21

39. Install oil pipe and water hose

40. Install left & right propeller shaft

41. Install left & right front wheel

42. Check engine oil for leakage

43. Install all connected wire harnesses and the cables on engine and vehicle body

22

Section 4  Camshaft Replacement

Figure 49

Vane-Type Pump V-Belt 

V/ Power Steering

Fan & Generator V-Belt

High Pressure Cable

Ventilation Pipe

V-Belt No.1

Cylinder Head

Cylinder 

Head Gasket

Crankshaft Bearing Cap

Crankshaft Timing Belt Washer

Crankshaft Counter Gear

Wave Gasket

Snap Ring

Camshaft

Camshaft No. 2

Oil Seal

Camshaft Timing Pulley

Fan Pulley

Generator Assembly

Crankshaft Or Pulley 

Cover Sub-Assembly

Timing Belt 

Cover No. 2

Air Filter Assembly W/ Hose

Right Engine Mounting

Seal

23

1. Disconnect all connected wire harnesses and the cable on the engine and the vehicle body

2. Remove air filter assembly with hose

3. Disconnect oil pipe and water hose

4. Loose positive and negative cables of the battery

5. Detach propeller shaft

6. Loose left & right rear engine mounting bracket after hoisting the engine.

7. Disconnect all other connectors between the engine and the vehicle body.

8. Remove engine per "Provison 20, Section 2, Chapter 2"

9. Remove A/C compressor to crankshaft pulleyV-belt

10. Remove power steering pump V- belt

11. Remove water pump fan pulley

12. Disconnect ignition coil and high voltage cables

13. Remove cylinder head cover sub-assembly

14. Remove generator assembly

15. Remove cylinder head cover sub-assembly

(a) Disconnect generator wire joint.

(b) Disconnect generator circuit

(c) Disconnect A/C compressor switch connector.

(e) Open wires clips.

(f) Disconnect wire harness from the cylinder head cover.

(g) Disconnect 2 ventilation PCV hoses from cylinder head cover.

(h) Remove 4 screws, 4 seal gaskets, cylinder head and gasket.

16. Remove generator assembly. See (Figure 50)

17. Remove timing belt cover

18. Remove crankshaft gear or pulley cover sub-assembly

19. Put the piston on Cylinder 1 to TDC compression position.

(a) Turn crankshaft pulley. Align its notch to the timing mark "O" on the

timing belt cover.

(b) Check if the mark "K" on camshaft  timing pulley is aligned to the

timing mark on the bearing cap. Turn crankshaft 360° if not.

20. Remove ignition coil assembly

21. Remove timing belt. See (Figure 51)

(a) Mark on the timing belt and the camshaft pulley. The mark on the

timing belt to the timing belt cover No. 1 should match.

(b) Remove rubber gasket from timing belt cover.

Figure 50

Figure 51

24

(c) Loose installing bolt of the idler. See (Figure 52). Move the pulley to

its far left and tighten it temporarily.

(d)  Remove the belt from the camshaft timing pulley.

Notice:

z

Hold the timing belt, the engagement of the crankshaft timing 

pulley and timing belt will not move.

z

Be careful not to drop anything into the timing belt cover.

z

Do not let the belt contact oils, water or dirt.

Figure 53

22. Remove the camshaft and the timing pulley. See (Figure 53)

(a)  Turn the camshaft hexagon head and loose pulley bolt.

(b)  Remove pulley bolt and timing pulley.

23. Remove camshaft. See (Figure 54)

Because the camshaft end play is quite small, keep camshaft horizontal  

when removing it.Take the following steps to avoid the damage:

(a) Remove the camshaft

 (1) Turn the camshaft to access the hole of the counter gear installed on camshaft drive gear.

Hint: The intake camshaft lobe of Cylinder 1 and 3 can push up their

own valve tappet.

 (2) Remove 2 bolts and bearing cap No. 1.

 (3) Install the counter gear on the intake camshaft with the service

bolt onto the drive gear.

 (4) Uniformly loose and detach 8 bearing cap bolts in several times

in the sequence shown in Figure 55.

 (5) Remove 4 bearing caps and camshaft.

If the camshaft can not be kept horizontal, lift it vertically. Reinstall the

bearing cap with 2 bolts. Alternatively loose and detach the bearing cap

bolts and lift the camshaft gear. See (Figure 56)

Figure 52

Figure 55

Figure 56

Figure 54