Toyota
Nissan Versa
 Sedan Service Manual
Engine » Engine mechanical (EM) » Camshaft
Removal and Installation

CAUTION:

The rotation direction indicated in the procedure is as viewed from the engine front.

REMOVAL

  1. Hold the bottom surface of the engine with a jack to remove the right engine mount assembly and the insulator.
  2. Remove rocker cover.
  3. Place cylinder No. 1 at TDC of its compression stroke:

    a. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover.

(B) : White paint mark (Not used for service)

CAMSHAFT

    b. Check that the matching marks on each of the camshaft sprockets are in the position as shown.

(1) : Timing chain

(2) : Camshaft sprocket (EXH)

(3) : Camshaft sprocket (INT)

(A) : Matching mark (Peripheral groove)

(B) : Pink link

(C) : Matching mark (Peripheral groove)

  • If not, rotate crankshaft pulley one more turn to align matching marks to the positions as shown.

CAMSHAFT

    c. Paint matching marks (A) on the timing chain links.

  1. Remove crankshaft pulley.
  2. Remove front cover.
  3. Secure the plunger of chain tensioner in the fully compressed position. Then, loosen the timing chain tension.

    a. Fully push down the lever (B) of chain tensioner (2) from the plug hole, and then insert the stopper pin (A) into the body side hole and secure the lever at the lowest position.

(C) : Front cover has been removed for clarity.

  • The tab is released by fully pushing the lever down. As a result, the plunger (1) can be moved.

NOTE:

Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example.

CAUTION:

The stopper pin must use a shape that cannot fall in the front cover if dropped.

CAMSHAFT

    b. Turn the crankshaft pulley (2) counterclockwise with the camshaft (EXH) (1) held. Apply the tension to the timing chain, and then push the plunger into the inside of chain tensioner.

CAUTION:

Hold the camshaft hexagonal part (A), and then secure the camshaft.

CAMSHAFT

    c. Pull out the stopper pin (A) of chain tensioner (2) side from plug hole. Lift the lever (B) up to align its hole position with the hole of the body.

(D) : Front cover has been removed for clarity.

  • When the lever hole (C) is aligned with the body hole position, the plunger (1) is secured.
  • When the protrusion parts of the plunger ratchet and the tab face each other, both hole positions are not aligned. At that time, correctly engage them and align these hole positions by slightly moving the plunger.

CAMSHAFT

  d. Insert the stopper pin into the body hole through the lever hole, and then secure the lever at the upper position.

  1. Remove timing chain.
  2. Remove camshaft sprocket (EXH) (1).

CAUTION:

  • Hold the camshaft hexagonal part (A), and then secure the camshaft.
  • Do not rotate crankshaft and camshaft separately, so as not to contact valve with piston.

NOTE:

The timing chain with the front cover installed is not disengaged from the crankshaft sprocket and it is not dropped into the front cover. Therefore, the timing chain tension holding device is not necessary.

    9. Turn the camshaft sprocket (INT) to the most advanced position.

CAMSHAFT

CAUTION:

Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position.

Make sure to follow the procedure exactly.

  • The sprocket (C) and vane (camshaft coupling) (B) are designed to spin and move within the range of a certain angle.
  • With the engine stopped and the vane in the most retarded angle, it will not spin because it is locked to the sprocket side by the internal lock pin (A).
  • If the camshaft sprocket bolts are turned in the situation described above, the lock pin will become damaged and cause malfunctions because of the increased horizontal load (cutting force) on the lock pin.

CAMSHAFT

  • Put the camshaft sprocket (INT) in the most advanced position:

    a. Remove camshaft bracket (No. 1) (1).

  : Engine front

  • Loosen the bolts in several steps, and then remove them.

CAMSHAFT

    b. Apply the following air pressure to the No. 1 journal oil hole (A) of camshaft (INT) (1) shown using an air gun.

Air pressure : 300 kPa (3.1 kg/cm2, 44 psi) or more

  • Apply the air pressure into the oil hole on the second groove from the front of camshaft thrust (B).
  • Proceed all the way through step "e" with the air pressure on.
  • Attach the rubber nozzle narrowed to the top of the air gun to prevent air leakage from the oil hole (A). Securely apply the air pressure to the oil hole.

WARNING:

Eye protection should be worn as needed.

CAUTION:

  • There are other oil holes in the side grooves. Do not use the incorrect oil holes.
  • Be sure not to damage the oil path with the tip of the air gun.
  • Wipe all the oil off the air gun to prevent oil from being blown all over along with the air, and the area around the air gun should be wiped with a rag when applying air pressure. Eye protection should be worn as needed.

NOTE:

The air pressure is used to move the lock pin into the disengage position.

CAMSHAFT

    c. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternately.

(A) : Air gun

(B) : Rubber nozzle

  • Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the arrow ( )].
  • Perform the work while continuously applying the air pressure to the oil hole.

CAMSHAFT

  • If the lock pin is not released, tap the camshaft sprocket (INT) lightly with a plastic hammer (A).
  • If the camshaft sprocket (INT) is not rotated counterclockwise even if the above procedures are performed, check the air pressure and the oil hole position.

CAMSHAFT

    d. While doing the above, once you hear a click (the sound of the internal lock pin disengaging) from inside the camshaft sprocket (INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position.

(C) : Lock pin engaged

(D) : Most advanced angle

  • Keep the air pressure on.
  • If there is no click, as soon as the vane side (camshaft side) starts moving independently of the sprocket, the lock pin has become disengaged.
  • Check that it is in the most advanced angle position by seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown.

CAMSHAFT

    e. Stop applying air pressure and release the camshaft (INT).

    f. Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position.

CAUTION:

No load is exerted on the stopper pin (spring reaction, etc.).

Since it comes out easily, secure it with tape (B) to prevent it from falling out.

NOTE:

The stopper pin shows one example of a hexagonal wrench for 2.5 mm (0.098 in) [length of inserted section: approximately15 mm (0.59 in)].

CAMSHAFT

    10. Remove the camshaft sprocket (INT):

    a. Keeping the camshaft hexagonal part (A) in place with the wrench, loosen the bolts for the camshaft sprocket (INT) (2).

(1) Camshaft (INT)

CAMSHAFT

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 prevent air from leaking out.

CAUTION:

The internal lock pin will get 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.

    11. Remove camshaft brackets (No. 2 to 5).

CAMSHAFT

  • Loosen bolts in several steps in the reverse order as shown.

(A) : EXH side

(B) : INT side

  : Engine front

NOTE:

The camshaft bracket (No. 1) has been already removed.

CAMSHAFT

  1. Remove camshaft (EXH).
  2. Remove camshaft (INT).
  3. Remove valve lifter.

- Identify installation positions, and store lifters without mixing them up.

  1. Remove intake valve timing control solenoid valve (1).
  2. Remove the alternator and bracket, remove the plug (2), and then remove the oil filter

CAMSHAFT

  1. Remove exhaust valve timing control solenoid valve.
  2. Remove the plug on the exhaust valve timing control solenoid valve and the oil filter.
  3. For component inspection after removal

INSTALLATION

CAUTION:

Do not reuse Orings or washers.

    1. Install oil filter (1) for intake and exhaust valve timing control solenoid valves.

CAUTION:

Do not reuse washers.

NOTE:

The intake side is shown as an example.

  • The oil filter (1) and washer (2) are assembled to the plug (3), and then install them in to the cylinder head.

CAMSHAFT

    2. Install intake and exhaust valve timing control solenoid valves.

  • Insert it straight into the cylinder head.
  • Tighten bolts.

    3. Install valve lifters.

  • If they are reused, install them in the original positions.

    4. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT):

NOTE:

This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (INT).

    a. Put the matching marks (A) on a line extending from the knock pin position of camshaft (INT) (1) front surface.

  • Put the marks on the visible position with the camshaft sprocket installed as shown.

    b. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (INT) (2) as shown.

  • Put the marks on the visible position with it installed to the camshaft.

CAMSHAFT

    5. Put a matching mark for positioning the camshaft (EXH) and the camshaft sprocket (EXH):

NOTE:

This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (EXH).

    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 camshaft sprocket 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.

CAMSHAFT

    6. Install camshaft

(1) : Camshaft (EXH)

(2) : Camshaft (INT)

(A) : Identification mark

  • Note that the camshafts (INT and EXH) have different shapes at the rear.

CAMSHAFT

  • Install camshafts to the cylinder head so that knock pins (A) on front end are positioned as shown.

(1) : Camshaft (EXH)

(2) : Camshaft (INT)

  : Upper side

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.

CAMSHAFT

    7. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown.

(A) : EXH side

(B) : INT side

  : Engine front

  • Install so that identification mark can be correctly read when viewed from the INT side.

CAMSHAFT

    8. Tighten bolts of camshaft brackets in the following steps, in numerical order as shown.

(A) : EXH side

(B) : INT side

: Engine front

    a. Tighten No. 9 to 11 in numerical order.

Camshaft bracket bolts : 1.96 N*m (2.0 kgm, 14 inlb)

    b. Tighten No. 1 to 8 in numerical order.

Camshaft bracket bolts : 1.96 N*m (2.0 kgm, 14 inlb)

    c. Tighten all bolts in numerical order.

Camshaft bracket bolts : 5.88 N*m (0.60 kgm, 52 inlb)

    d. Tighten all bolts in numerical order.

Camshaft bracket bolts : 10.4 N*m (1.1 kgm, 8 ftlb)

CAMSHAFT

    9. Install the camshaft sprocket (INT and EXH) to the camshaft (INT and 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.

CAMSHAFT

    10. Tighten the camshaft sprocket bolt (INT and EXH).

(1) : Camshaft sprocket (EXH)

CAUTION:

Hold the camshaft hexagonal part (A), using a suitable tool to secure the camshaft.

CAMSHAFT

    11. Install the camshaft (INT and EXH) to the camshaft sprocket (INT and EXH) (2 and 3) while aligning the matching mark (marked when timing chain is removed) (A) and the pink link (B) of camshaft sprocket (INT and EXH).

(1) : Timing chain

(C) : Matching mark (peripheral groove)

  • If the positions of knock pin and pin groove are not aligned, move the camshaft (EXH) slightly to correct these positions.

CAMSHAFT

    12. Pull out the stopper pin (A), and then apply the tension to the timing chain by rotating the crankshaft pulley clockwise slightly.

(1) : Plunger

(2) : Chain tensioner

(B) : Lever

(C) : Lever hole

(D) : Front cover has been removed for clarity.

CAMSHAFT

  1. Pull out the stopper pin of chain tensioner.
  2. Install front cover.
  3. Return the camshaft sprocket (INT) in the most retarded position:

    a. Remove the stopper pin (A) from the camshaft sprocket (INT).

(B) : Tape

CAMSHAFT

    b. Turn the crankshaft pulley (1) slowly clockwise (A) and return the camshaft sprocket (INT) to the most retarded angle position.

CAMSHAFT

  • When first turning the crankshaft, the camshaft sprocket (INT) will turn. Once it is turned more, and the vane (camshaft) also turns, then it has reached the most retarded angle position.

(B) : Stopper pin hole

(C) : Most advanced angle

(D) : Lock pin engaged

  • The most retarded angle position can be checked by seeing if the stopper pin groove (A) is shifted clockwise.
  • After spinning the crankshaft slightly in the counterclockwise direction, you can check the lock pin has joined by seeing if the vane (camshaft) and the sprocket move together.

CAMSHAFT

    16. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.

  • Tighten bolts with it completely inserted.

    17. Check and adjust valve clearance.

    18. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION

  • Before starting engine, check oil/fluid levels, including engine coolant and engine oil. If less than required quantity, fill to the specified level.
  • Use procedure below to check for fuel leakage.
  • Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
  • Start engine. With engine speed increased, check again for fuel leakage 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 leakage 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 specified level, if necessary.
  • Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission/ transaxle fluid A/T and CVT Models Leakage Level/Leakage Leakage
M/T Models Level/Leakage Leakage Level/Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas Leakage

*Power steering fluid, brake fluid, etc.

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