REMOVAL AND INSTALLATION


caution *: Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Engine Cover Removal (Refer to ).
  • Throttle Body Assembly Removal (Refer to GROUP 13D - Throttle Body ).
  • EGR Valve and EGR Pipe B Removal (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Air Inlet Pipe Removal <4M41> (Refer to GROUP 15 - Inlet Manifold ).
  • Fuel Injector Assembly, Common Rail Assembly and Rocker Cover Assembly Removal (Refer to GROUP 13D - Fuel Injector and Common Rail ).

 Post-installation Operation
  • Fuel Injector Assembly, Common Rail Assembly and Rocker Cover Assembly Installation (Refer to GROUP 13D - Fuel Injector and Common Rail ).
  • Air Inlet Pipe Installation <4M41> (Refer to GROUP 15 - Inlet Manifold ).
  • EGR Valve and EGR Pipe B Installation (Refer to GROUP 17 - Emission Control, EGR Valve and EGR Cooler ).
  • Throttle Body Installation (Refer to GROUP 13D - Throttle Body ).
  • Engine Cover Installation (Refer to ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).




Removal steps

>>E<<
 1.
 Chain tensioner

>>D<<
 2.
 Chain tensioner gasket


3.
 Upper guide plate
<<A>>
 >>C<<
 4.
 Camshaft sprocket

>>B<<
 5.
 Camshaft cap


6.
 Inlet camshaft assembly


7.
 Exhaust camshaft assembly

>>A<<
 8.
 Camshaft holder


9.
 Rocker arm short


10.
 Rocker arm long

REMOVAL SERVICE POINT

<<A>> CAMSHAFT SPROCKET REMOVAL

1.
caution Never turn the crankshaft anti-clockwise.
Turn the crankshaft clockwise, align the mating marks on the camshaft sprocket with the mark plates (yellow) on the timing chain to set No.1 cylinder to TDC (Top Dead Centre) of its compression stroke.

2.
caution
  • Do not lock the camshaft using the timing chain.
  • The camshaft sprocket bolt is left threaded, so the arrow indicating its tightening direction is marked on the bolt head. To loosen this bolt, turn the bolt to the opposite direction of the arrow.
  • The timing chain must be attached to the camshaft sprockets.
Hold the hexagonal part of the camshaft with an open end wrench, loosen the camshaft sprocket bolts, and then remove the camshaft sprockets with the timing chain still attached.
3.Tie up the timing chain and the camshaft sprocket with a cord to prevent the mating mark misalignment.

INSTALLATION SERVICE POINTS

>>A<< CAMSHAFT HOLDER INSTALLATION

1.Camshaft holder No.1 to 5 are the same shape.
2.Be sure to install team in order of their cap numbers.

>>B<< CAMSHAFT CAP INSTALLATION

1.Camshaft cap No.1 to 5 are the same shape.
2.Be sure to install team in order of their cap numbers.

>>C<< CAMSHAFT SPROCKET INSTALLATION
caution
  • Do not lock the camshaft using the timing chain.
  • The camshaft sprocket bolt is left threaded, so the arrow indicating its tightening direction is marked on the bolt head.
1.Install the camshaft sprockets to the camshafts with the timing chain attached.

2.Hold the hexagonal part of the camshaft with an open end wrench in the same manner as removal.
3.Apply a small amount of engine oil to the camshaft sprocket bolt thread and the flange, and then tighten to the specified torque.
Tightening torque: 88 ± 10 N·m

>>D<< CHAIN TENSIONER GASKET INSTALLATION

Place the chain tensioner gasket with its silicone print facing toward the chain tensioner side.

>>E<< CHAIN TENSIONER INSTALLATION

1.Raise the cam, and then push in the plunger.

2.Lock the plunger using a hook.
3.
caution To install the chain tensioner, always push in the plunger. If you fail to do this, the timing chain will be excessively tensioned, causing damage.
Install the chain tensioner to the cylinder head.
4.
caution If the crankshaft is turned anti-clockwise after the chain tensioner is installed, the plunger will be excessively tensioned, causing the plunger to go beyond the cam inside the chain tensioner.
note If the crankshaft is turned clockwise after the chain tensioner is installed, the plunger is automatically unhooked. Then its internal ratchet mechanism adjusts the timing chain tension.
Turn the crankshaft clockwise.