REMOVAL AND INSTALLATION


caution *Remove and assemble the marked parts in each cylinder unit.
Pre-removal operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Ignition Coil and Spark Plug Removal (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Cylinder Head Cover Assembly Removal (Refer to ).
  • Engine Oil Pan Removal (Refer to ).
  • Timing Chain Removal (Refer to ).

 Post-installation operation
  • Timing Chain Installation (Refer to ).
  • Engine Oil Pan Installation (Refer to ).
  • Valve Clearance Check (Refer to ).
  • Cylinder Head Cover Assembly Installation (Refer to ).
  • Ignition Coil and Spark Plug Installation (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).




Removal steps
<<A>>
 >>D<<
 1.
 Front camshaft bearing cap
<<A>>
 >>D<<
 2.
 Camshaft bearing cap (exhaust side)


3.
 Camshaft and camshaft sprocket assembly (exhaust side)
<<A>>
 >>D<<
 4.
 Camshaft bearing cap (inlet side)


5.
 Camshaft and V.V.T. sprocket assembly (Inlet side)
<<B>>
 >>C<<
 6.
 Valve tappet
<<C>>
 >>B<<
 7.
 Valve spring retainer lock


8.
 Valve spring retainer


9.
 Valve spring
<<D>>
 >>A<<
 10.
 Valve stem seal

REMOVAL SERVICE POINTS

<<A>> FRONT CAMSHAFT BEARING CAP / CAMSHAFT BEARING CAP REMOVAL
1.Temporarily install the engine oil pan which was removed at the timing chain removal (Refer to ).
2.
caution When supporting the engine and transmission assembly with a garage jack, be careful not to deform the engine oil pan.
Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transmission assembly.


3.Remove special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the timing chain was removed.

4.In accordance with the numerical order shown in the illustration, remove the front camshaft bearing cap first, and then remove the installation bolt of each camshaft bearing cap.

<<B>> VALVE TAPPET REMOVAL
caution
  • Do not use pliers or other tools to remove the valve tappets. Always remove them by hands.
  • When reusing the removed valve tappet, it has to be installed in the same position as before. Be sure to put a tab that shows the original installation position on the valve tappet when storing it.

Remove all of the valve tappets by hands.

<<C>> VALVE SPRING RETAINER LOCK REMOVAL

1.Screw in special tool retainer holder attachment (MB992090) to special tool valve spring compressor (MD998772), and assemble special tool retainer holder C (MB992089).
2.
caution When removing the valve spring retainer lock, leave the piston of the 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.
Install special tool (MD998772) (with special tools MB992090 and MB992089 attached) to the cylinder head and compress the valve spring. Then, remove the valve spring retainer lock.

<<D>> VALVE STEM SEAL REMOVAL

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.

INSTALLATION SERVICE POINTS

>>A<< VALVE STEM SEAL INSTALLATION
1.Apply a small amount of engine oil to the valve stem seals.

2.
caution
  • Valve stem seals cannot be reused.
  • Do not damage the wall of the tappet hole when installing the valve stem seal.
  • Special tool valve stem seal installer (MB991994) must be used to install the valve stem seal. Improper installation of the valve stem seal could result in oil leaking past the valve guide.
Use special tool valve stem seal installer (MB991994) to press-fit a new valve stem seal in the valve guide using the valve stem area as a guide.
note Use the special tool, on which the number "MB991994A" is stamped.

>>B<< VALVE SPRING RETAINER LOCK INSTALLATION

In the same manner as removal, use special tool valve spring compressor (MD998772) with special tool retainer holder attachment (MB992090) and special tool retainer holder C (MB992089) attached to compress the valve spring, and install the valve spring retainer lock.

>>C<< VALVE TAPPET INSTALLATION
1.Apply a small amount of engine oil to the valve tappets.

2.
caution
  • Do not use pliers or other tools to install the valve tappets. Always install them by hand.
  • Be sure to install the valve tappets in the same position as before.
Install the valve tappet to the cylinder head by hand.

>>D<< CAMSHAFT BEARING CAP/FRONT CAMSHAFT BEARING CAP INSTALLATION

1.The No. 2 to No. 5 bearing caps are equally shaped for both the inlet and exhaust camshafts. Be sure to correctly install them by referring to the identification marks.
Identification mark (stamped on the front and No. 2 to No. 5 bearing caps)
    I: Inlet
    E: Exhaust
2.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:

    11 ± 1 N·m (Camshaft bearing cap mounting bolts)
    20 ± 1 N·m (Front camshaft bearing cap mounting bolts)


3.Install special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the timing chain was removed (Refer to ).
4.Remove the garage jack which supports the engine and transmission assembly.
5.Remove the engine oil pan installed temporarily.