REMOVAL AND INSTALLATION

<Except vehicles for Thailand> Removal steps <<A>> 1. Service hole bolt <<A>> 2. Gasket <<A>> >>B<< 3. Camshaft sprocket bolt <<A>> >>B<< 4. V.V.T. sprocket bolt <<A>> >>B<< 5. Front camshaft bearing cap <<A>> >>B<< 6. Camshaft bearing cap <<A>> >>B<< 7. Exhaust camshaft <<A>> >>B<< 8. Inlet camshaft <<B>> >>A<< 9. Valve tappet

<Vehicles for Thailand> Removal steps <<A>> 1. Service hole bolt <<A>> 2. Gasket <<A>> >>B<< 3. Camshaft sprocket bolt <<A>> >>B<< 4. V.V.T. sprocket bolt <<A>> >>B<< 5. Front camshaft bearing cap <<A>> >>B<< 6. Camshaft bearing cap <<A>> >>B<< 7. Exhaust camshaft <<A>> >>B<< 8. Inlet camshaft <<B>> >>A<< 9. Valve tappet

1. caution Never turn the crankshaft anti-clockwise. Turn the crankshaft clockwise, and align the timing mark of the camshaft sprocket and that of the V.V.T. sprocket assembly (the groove of V.V.T. sprocket assembly side face). Then set No.1 cylinder to the TDC. 2.Remove the service hole bolt and gasket from the timing chain case.

3.While holding the inlet camshaft hexagonal portion or square portion with a wrench or a similar tool, slightly turn the exhaust camshaft clockwise to tighten the timing chain at the timing chain tensioner side and shorten the plunger of the timing chain tensioner. note This allows the plate on the timing chain tensioner to move to the lower end position.

4. caution After a pin or a similar tool is inserted, never rotate the crankshaft. Otherwise, the timing chain will be out of alignment. Insert a pin (3-mm diameter) or a similar tool to the timing chain tensioner through the service hole as shown with the timing chain tensioner plunger compressed. If the inserted pin or a similar tool slides laterally, it may be disengaged from the plate hole. Repeat from step 3. note Pull out the pin or a similar tool after installing the camshaft sprocket bolt.

5.Put a paint mark on the V.V.T sprocket and the timing chain. 6.Fix the camshaft sprocket and the timing chain using a cable band or a similar tool.

7.While holding the exhaust camshaft hexagonal portion or square portion with a wrench or a similar tool, loosen the camshaft sprocket bolt.

8.While holding the inlet camshaft hexagonal portion or square portion using a wrench or a similar tool, use special tool torque wrench adapter (MB991992) to loosen the V.V.T. sprocket bolt. 9.Loosen the camshaft sprocket bolt and V.V.T. sprocket bolt immediately before they touch the inside of the timing chain case. 10. caution This action slackens the timing chain. If you attempt to remove the camshaft without doing this, the journal at the cylinder head side will be damaged. Slide the camshaft sprocket towards the front of the engine to disengage the exhaust camshaft dowel pin. Slide the V.V.T. sprocket assembly towards the front of the engine to disengage the inlet camshaft dowel pin. This action slackens the timing chain. note If the dowel pin is difficult to disengage, slide the sprocket towards the front of the engine by twisting the hexagonal portion or square portion to the right and left slightly with a wrench.

11.Loosen the front camshaft bearing cap mounting bolts, and then loosen each camshaft bearing cap mounting bolts in the order shown. Remove the front camshaft bearing cap and each camshaft bearing cap. 12. caution When you lift the camshaft forcibly, the journal may be damaged. Never use any tools, but lift it with your hands. Lift the exhaust camshaft horizontally while rotating it slightly clockwise with your hands. Then remove it from the groove on the cylinder head. note Holding the rear end of the exhaust camshaft facilitates lifting it.

13. caution Do not turn the crankshaft after removing the camshaft sprocket with the timing chain. Remove the camshaft sprocket bolt, and then remove the exhaust camshaft. 14. caution Do not turn the crankshaft after removing the V.V.T. sprocket assembly with the timing chain. Lift the inlet camshaft vertically to remove the V.V.T. sprocket bolt. Then remove the inlet camshaft. 15. caution After disconnecting the camshaft sprocket and the V.V.T. sprocket assembly (with the timing chain for each) from the camshaft, do not dislocate the camshaft sprocket, the V.V.T. sprocket assembly, and the timing chain. After removal, place the camshaft sprocket and timing chain assembly, and the V.V.T. sprocket and timing chain assembly on the timing chain case assembly

1.Apply a proper minimum quantity of engine oil to the following points. Inlet camshaft end Insertion hole in V.V.T. sprocket assembly (all over inside and outside surfaces) Threads and head of V.V.T. sprocket bolt Bearing surface of V.V.T. sprocket bolt 2.Temporarily assemble the inlet camshaft to the V.V.T. sprocket assembly (but do not engage the sprocket with the dowel pin).

3.Install the camshaft bearing cap at the inlet side to secure the inlet camshaft. Camshaft bearing caps (No.2 to 4) are identical. To avoid confusion (bearing cap No. and inlet/exhaust side), confirm each identification mark and face the front mark towards the direction shown before installing them. Identification mark (engraved on the front and bearing caps No.2 - 4) I: Inlet side E: Exhaust side

4.Engage the V.V.T. sprocket with the dowel pin by twisting the hexagonal portion or square portion on the inlet camshaft with a wrench slightly. 5.Rotate the exhaust camshaft anti-clockwise with your hand slightly to engage it with the groove on the cylinder head journal (but do not engage the sprocket with the dowel pin). 6.Install the camshaft bearing cap and the front camshaft bearing cap at the exhaust side to secure the exhaust camshaft. 7.Engage the dowel pin with the hole on the camshaft sprocket by twisting the hexagonal portion or square portion on the exhaust camshaft with a wrench slightly. note If it is difficult to insert the exhaust camshaft into the camshaft sprocket, check that the hole on the sprocket is aligned with the dowel pin. Then press in the sprocket again by twisting the camshaft to the right and left slightly.

8.Tighten each camshaft bearing cap mounting bolts to the specified torque in the order shown, and then tighten the front camshaft bearing cap mounting bolts as well. Tightening torque: Camshaft bearing cap mounting bolts: 11 ± 1 N·m Front camshaft bearing cap mounting bolts: 20 ± 1 N·m

9. caution Check that the sprocket has been engaged with the dowel pin securely, and then tighten the bolt. While holding the inlet camshaft hexagonal portion or square portion using a wrench or a similar tool, use special tool torque wrench adapter (MB991992) to tighten the V.V.T. sprocket bolt to the specified torque. Since the V.V.T. sprocket bolt is tightened by special tool, calculate the tightening torque by the following formula. Tightening torque: (65 ± 5) × {L ÷ (L + 150)} N·m 65 ± 5: Tightening torque of the V.V.T. sprocket bolt (unit: N·m) L: Distance between the centre of a torque wrench drive and of its handle (unit: mm) 150: Length of special tool (unit: mm)

10. caution Check that the sprocket has been engaged with the dowel pin securely, and then tighten the bolt. After all of the sprocket bolts have been tightened, check that the sprockets are directly in line without any slant. If the engine is started while the sprockets are installed improperly, the engine will be damaged. While holding the exhaust camshaft hexagonal portion or square portion using a wrench or similar tool, tighten the camshaft sprocket bolt to the specified torque. Tightening torque: 92 ± 13 N·m