REMOVAL AND INSTALLATION


caution *Remove and assemble the marked parts in each cylinder unit.
Pre-removal Operation
  • Air Intake Pipe Removal (Refer to GROUP 15 - Air Cleaner ).

 Post-installation Operation
  • Air Intake Pipe Installation (Refer to GROUP 15 - Air Cleaner ).




Removal steps


1.
 Breather hose connection


2.
 PCV hose connection


·
 Ignition coil (Refer to GROUP 16 - Ignition System, Ignition Coil ).


3.
 Timing belt front upper cover


4.
 Engine hanger


5.
 Rocker cover assembly
<<A>>
 >>D<<
 6.
 Rocker arm and shaft assembly
<<B>>
 >>C<<
 7.
 Valve spring retainer lock


8
 Valve spring retainer

>>B<<
 9.
 Valve spring

>>A<<
 10.
 Valve stem seal


11.
 Valve spring seat

REMOVAL SERVICE POINTS

<<A>> ROCKER ARM AND SHAFT ASSEMBLY REMOVAL
caution Never disassemble the rocker arm, shaft and lash adjuster assembly.

Before rocker arm and shaft assembly removal, install special tool lash adjuster holder (MD998443) as shown in the illustration so that the lash adjusters will not fall out.

<<B>> VALVE SPRING RETAINER LOCK REMOVAL
caution When removing valve spring retainer lock, leave the piston of each cylinder in the TDC (Top Dead Centre) position. The valve may fall into the cylinder if the piston is not properly in the TDC position.

Use special tool valve spring compressor (MD998772) to compress the valve spring, remove the valve spring retainer lock.

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION

1.
caution
  • Valve stem seal for intake valves and for exhaust valves are different. Be sure to install the correct ones.
  • The valve stem seal must not be reused.
  • Do not damage the tappet wall during assembly.
  • Be sure to use a special tool to install the valve stem seal. Poor installation causes oil loss via valve guides.
  • If oil is not applied, the valve stem seal may rise to the surface after it is press fitted.
Apply a small amount of engine oil to the press-fit part and lip part of the new valve stem seal.
2.Use a special tool to install the valve stem seal, obeying the following procedures.

3.Special tool valve stem seal installer adjustable (MB992922) is composed of the components shown in the illustration.
1: Chuck
2: Sleeve
3: Lock nut (small)
4: Outer pipe
5: Lock nut (large)
6: Guide pin (5.9)
7: Guide pin (4.9)
8: Cap
9: Guide pin (5.4)

4.Adjust the inside chuck diameter, obeying the following procedures.
(1) Install the sleeve to the chuck as shown in the illustration.
(2) Install the shoulder of the valve stem seal to the chuck, aligning with the outer circumference line of the chuck as shown in the illustration.
(3) Turn the sleeve to wring the chuck.
(4) Stop the sleeve at the position where you can easily remove the valve stem seal by hand.
(5) Use the (small) lock nut to fix the sleeve.




5.Adjust the stem seal insertion length, obeying the following procedures.
(1) The position, in which the end face of the outer pipe is aligned with the outer circumference line of the chuck, is 0 mm of the insertion length. Insert the chuck and the sleeve into the outer pipe to fit the nut as shown in the illustration.
(2) Turn the chuck to adjust the valve stem seal insertion length.
note The insertion length can change by 1 mm per the chuck turn.
To easily know how many times the chuck is turned, put the mark at the position shown in the illustration.
(3) Use a vernier caliper to measure the checkpoint (L1) of the insertion length shown in the illustration. Check the insertion length.
Standard value: 16.0 mm
(4) Use the (large) lock nut to fix the sleeve.

6.Install the cap to the chuck.
7.Apply the engine oil to the valve stem seal to set the chuck.
8.Install the valve spring seat.

9.Use the plastic hammer to insert the valve stem seal.

>>B<< VALVE SPRINGS INSTALLATION

Install the valve springs with its identification colour painted end facing the locker arm.

>>C<< VALVE SPRING RETAINER LOCKS INSTALLATION

Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal, install the valve spring retainer lock.

>>D<< ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION
1.Ensure that all rocker arms do not press against the valve, then pre-tighten the rocker arm, shaft and lash adjuster assembly with the assembling bolt.

2.Check that notches in the each rocker shaft are facing the direction shown in the illustration.

3.Install the rocker shaft spring so that it is at a right angle against the spark plug guide.
4.Tighten the mounting bolts to the specified torque.
Tightening torque: 31 ± 3 N·m

5.Remove special tool lash adjuster holder (MD998443).