REMOVAL AND INSTALLATION

Removal steps 1. Breather hose 2. Oil filler cap 3. Packing >>G<< 4. Rocker cover 5. Gasket "A" 6. Gasket "B" 7. Gasket "C" >>F<< 8. Stud >>E<< 9. Oil seal >>D<< 10. Oil seal >>C<< 11. Semi-circular packing >>B<< 12. Eye bolt >>B<< 13. Fuel leakage pipe >>B<< 14. Fuel leak-off gasket >>B<< 15. Injector holder bolt >>B<< 16. Injector supporter >>B<< 17. Pivot boss >>B<< 18. Fuel injector >>B<< 19. Nozzle gasket <<A>> >>A<< 20. Camshaft sprocket bolt 21. Camshaft sprocket 22. Timing belt rear cover

Remove the camshaft sprocket bolt holding the hexagonal area of the camshaft with a wrench.

Tighten the camshaft sprocket bolt to the specified torque of 88 ± 10 N·m holding the hexagonal area of the camshaft with a wrench.

1.Clean the fuel injector assembly (nozzle) and the cylinder head (fuel injector insertion hole) by following the procedure below. (1) caution Do not clean the injection part of the nozzle with a resin spatula. Using a resin spatula, scrape off the carbon deposit on the fuel injector nozzle side face ("A" shown in the figure). (2) Spray carburettor cleaner (MZ100139) or equivalent to the nozzle side face ("A" shown in the figure). (3) caution Do not touch the injection part of the nozzle with hand or wipe it with a rag. Leave the injection part for a while until the carbon deposit melts down, and then blow air to the injection part. (4) Insert special tool ornament remover (MB990784) to the cylinder head (fuel injector insertion hole) with turning the special tool as shown, and scrape off the carbon deposit. (5) caution In order to prevent carbon from adhering to the inner surface of the cylinder, blow air with the piston in the TDC position. Remove the special tool, and blow off the carbon deposit on the cylinder head (fuel injector insertion hole) by air. (6) Check that there is no carbon deposit remaining on the contact surface of the fuel injector nozzle gasket. note Repeat step 4 to step 6 several times until the carbon deposit is completely removed.

2.Install the nozzle gasket, fuel injector, pivot boss, and injector supporter to the cylinder head as shown in the figure. 3.Apply a small amount of engine oil to the seat surface and thread of injector holder bolt, and then temporarily tighten the bolt to the cylinder head. 4.Set the fuel leak-off gasket to the fuel leakage pipe, and temporarily tighten to the fuel injector and to the cylinder head using the eye bolt. 5.Tighten the eye bolt of the fuel injector side to the specified torque. Tightening torque: 15 ± 2 N·m 6.Tighten the eye bolt of the cylinder head side to the specified torque. Tightening torque: 15 ± 2 N·m 7.Tighten the injector holder bolt to the specified torque. Tightening torque: 10 ± 1 N·m

8. caution When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured. When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure. Using special tool angle gauge (MB991614), tighten the injector holder bolt in the illustrated sequence by a further 120 to 125°.

1.Apply specified sealant to portions indicated in illustration. Specified sealant: ThreeBond 1217G or equivalent note Install the semi-circular packing immediately applying sealant. 2. 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. Install the semi-circular packing.

Using a proper socket wrench, the oil seal is pressed and fit into the rocker cover.

Using a proper socket wrench, the oil seal is pressed and fit into the rocker cover.

1.Apply specified sealant to portions indicated in illustration. Specified sealant: ThreeBond 1217G or equivalent note Install the rocker cover immediately applying sealant.

2. caution Pay attention that the connector does not damage the seal lip when inserting the rocker cover. Slightly press the oil seal lip to the place in the opposite direction of the connector, shown in the illustration. 3.Leave enough clearance for the connector to avoid touching the seal lip.

4.Slowly get the seal lip through not making contact with the connector. 5.Put the rocker cover down to the installation location.

6.Check that the injector-sealing surface has the seal lip.

7.In accordance with the tightening order shown in the illustration, tighten bolts to 2.5 ± 1.5 N·m. 8. 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. Again, in accordance with the tightening order shown in the illustration, tighten bolts to the specified torque of 10 ± 2 N·m.