REMOVAL AND INSTALLATION

Inlet camshaft removal steps · Timing belt (Refer to ). · Rocker cover (Refer to GROUP 13B - Fuel Injector ). · Valve clearance check and adjustment (Refer to ). <<A>> >>K<< 1. Camshaft sprocket 2. Timing belt rear cover >>J<< 3. Camshaft oil seal <<B>> >>I<< 4. Camshaft bearing cap, front left >>I<< 5. Inlet oil pipe 6. O-ring <<B>> >>I<< 7. Camshaft bearing cap, left >>H<< 8. Inlet camshaft assembly >>G<< 9. Snap ring >>G<< 10. Wave washer >>G<< 11. Sub gear >>G<< 12. C-spring >>G<< 13. Dowel pin >>G<< 14. Inlet camshaft Exhaust camshaft removal steps · Rocker cover (Refer to GROUP 13B - Fuel Injector ). · Valve clearance check and adjustment (Refer to ). <<B>> >>F<< 15. Camshaft bearing cap, front right >>F<< 16. Exhaust oil pipe 17. O-ring <<B>> >>F<< 18. Camshaft bearing cap, right >>E<< 19. Exhaust camshaft Valve stem seal removal steps · Timing belt (Refer to ). · Rocker cover (Refer to GROUP 13B - Fuel Injector ). · Valve clearance check and adjustment (Refer to ). <<A>> >>K<< 1. Camshaft sprocket 2. Timing belt rear cover >>J<< 3. Camshaft oil seal <<B>> >>I<< 4. Camshaft bearing cap, front left >>I<< 5. Inlet oil pipe 6. O-ring <<B>> >>I<< 7. Camshaft bearing cap, left >>H<< 8. Inlet camshaft assembly <<B>> >>F<< 15. Camshaft bearing cap, front right >>F<< 16. Exhaust oil pipe 17. O-ring <<B>> >>F<< 18. Camshaft bearing cap, right >>E<< 19. Exhaust camshaft >>D<< 20. Rocker arm assembly >>D<< 21. Nut >>D<< 22. Adjusting screw 23. Pivot bolt >>C<< 24. Stem end cap <<C>> >>B<< 25. Valve spring retainer lock 26. Valve spring retainer 27. Valve spring <<D>> >>A<< 28. Valve stem seal >>A<< 29. Valve spring seat

1.Use the following special tools to hold the camshaft sprocket. Front hub and flange yoke holder (MB990767) Pin (MD998719) 2.Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket.

Loosen the mounting bolts of the camshaft bearing cap in the order shown in the figure. Then, remove the camshaft bearing caps.

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

Use special tool valve stem seal pliers (MB992085) to nip the base of the stem seal (where the outside diameter is larger) securely, and remove it by twisting it to the left and right.

3.Special tool valve stem seal installer adjustable (MB992922) is composed of the components shown in the illustration. 1: Chuck 2: Sleeve 3: Rock nut (small) 4: Outer pipe 5: Rock 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) rock 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. L1: 19.8 mm (4) Use the (large) rock 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.

Install the stem end cap. Make sure that the stem end cap is in close contact with the stem end faces of the inlet and exhaust valve.

1.Screw the adjusting screw into the rocker arm assembly, and then temporarily assemble using a nut so that the adjusting screw protrusion becomes the dimension shown in the figure. 2.Apply the engine oil to the sliding surface of the parts below. Roller and valve-side sliding area of the rocker arm assembly Concave spherical surface of pivot bolt or spherical surface of adjusting screw

3.Place the rocker arm assembly onto the pivot bolt and the stem end cap as shown in the figure.

2.Set the timing mark of the exhaust camshaft in the position shown in the figure.

1.Place the camshaft bearing cap onto the camshaft journal section. note Install the camshaft bearing cap in numerical order in accordance with "cap No." stamped on the upper surface of the bearing cap. 2.Install the O-ring into the exhaust oil pipe, taking care not to damage or twist it. 3.Install the exhaust oil pipe to the camshaft bearing cap.

4.Tighten the mounting bolts of the camshaft bearing cap to the specified torque in the order shown in the figure. Then, fix the camshaft bearing cap and exhaust oil pipe to the cylinder head. Tightening torque: M6: 11 ± 1 N·m M8: 20 ± 1 N·m

1.Fix the inlet camshaft hexagonal area using a vice or other devices.

2.Press fit the dowel pin into the inlet camshaft and sub gear so that the dimension becomes as shown in the figure.

3.After contacting the C-spring with the dowel pin as shown in the figure, set to the inlet camshaft.

4.Set the sub gear to the inlet camshaft so that the sub gear dowel pin is inside the A range between the C-spring and inlet camshaft dowel pin as shown in the figure. 5.Assemble the wave washer and the snap ring to the inlet camshaft.

1.Fix the hexagonal area of inlet camshaft assembly using a vice or other devices.

2. caution Avoid turning the sub gear than necessary. Set the flange bolts (M6 x 20) to 2 locations of sub gear. Then, using a screwdriver, turn the sub gear clockwise until the sub gear hole (M8) and the threaded hole (M6) of inlet camshaft gear match as shown in the figure.

3.Temporarily fix the sub gear using the bolt (M6 x 20). At this time, screw in until the bolt head is in contact with the sub gear. 4.Remove the 2 flange bolts (M6 x 20) installed in the step 2. 5.Remove from the vice or other devices the inlet camshaft assembly to which the sub gear being temporarily fixed. Then, apply the engine oil to the cam face, journal section, thrust face, and gear teeth face of inlet camshaft assembly.

6.Set the timing marks of the inlet camshaft assembly and exhaust camshaft in the position shown in the illustration.

1.Place the camshaft bearing cap onto the camshaft journal. note Install the camshaft bearing cap in numerical order in accordance with "cap No." stamped on the upper surface of the bearing cap. 2.Install the O-ring into the inlet oil pipe, taking care not to damage or twist it. 3.Install the inlet oil pipe to the camshaft bearing cap.

4. caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine. Apply specified sealant to the matching area of the cylinder head assembly and the camshaft bearing cap as shown, and install the camshaft bearing cap to the cylinder head assembly. Specified sealant: ThreeBond 1212D or equivalent note Install the bearing cap immediately applying sealant.

5.Tighten the mounting bolts of the camshaft bearing to the specified torque in the order shown in the figure. Then, fix the camshaft bearing cap and inlet oil pipe to the cylinder head. Tightening torque: M6: 11 ± 1 N·m M8: 20 ± 1 N·m 6.Remove the bolt (M6 x 20) used to temporarily fix the sub gear of inlet camshaft assembly.

2.Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seal as shown.