REMOVAL AND INSTALLATION







Camshaft removal steps


·
Air cleaner intake hose and air cleaner assembly (Refer to GROUP 15 - Air Cleaner <4B1> ).


·
Strut tower bar (Refer to GROUP 42A - Strut Tower Bar ).


1.
Engine upper cover


·
Ignition coil (Refer to GROUP 16 - Ignition System, Ignition Coil <4B1> ).


2.
Breather hose connection


3.
PCV hose connection


4.
Control wiring harness connection


5.
engine oil filler cap
<<A>>
>>G<<
6.
Rocker cover assembly
<<B>>

·
Cylinder No. 1 compression top dead centre setting (only at removal).


·
Valve clearance adjustment (Refer to ) (only at installation).


7.
Timing chain upper guide


8.
Service hole bolt
<<C>>

·
Camshaft and camshaft sprocket assembly (exhaust side) removal preparatory operation (only at removal).
<<D>>
>>F<<
9.
Camshaft bearing front cap assembly

>>E<<
10.
Camshaft bearing
<<E>>
>>D<<
11.
Camshaft bearing oil feeding cap (exhaust side)
<<E>>
>>D<<
12.
Camshaft bearing cap (exhaust side)
<<E>>
>>D<<
13.
Camshaft bearing cap (exhaust side)
<<E>>
>>D<<
14.
Camshaft bearing thrust cap (exhaust side)
<<F>>
>>E<<
15.
Camshaft and camshaft sprocket assembly (exhaust side)
<<G>>
>>B<<
16.
Camshaft sprocket (exhaust side)
<<G>>
>>B<<
17.
Camshaft (exhaust side)

>>E<<
18.
Camshaft bearing
<<E>>
>>D<<
19.
Camshaft bearing oil feeding cap (inlet side)
<<E>>
>>D<<
20.
Camshaft bearing cap (inlet side)
<<E>>
>>D<<
21.
Camshaft bearing cap (inlet side)
<<E>>
>>D<<
22.
Camshaft bearing thrust cap (inlet side)

>>C<<
23.
Camshaft and camshaft sprocket assembly (inlet side)
<<G>>
>>B<<
24.
Camshaft sprocket (inlet side)
<<G>>
>>B<<
25.
Camshaft (inlet side)



Oil control valve removal steps


·
Alternator and others belt (Refer to ).
<<H>>

26.
Power steering oil pump assembly


27.
Oil control valve connector (inlet side)
<<I>>
>>A<<
28.
Oil control valve (inlet side)

>>A<<
29.
O-ring


30.
Oil control valve connector (exhaust side)
<<I>>
>>A<<
31.
Oil control valve (exhaust side)

>>A<<
32.
O-ring

REMOVAL SERVICE POINTS



<<A>> ROCKER COVER ASSEMBLY REMOVAL



Loosen the rocker cover assembly mounting bolts in the order of number shown in the figure, and remove the rocker cover assembly.

<<B>> CYLINDER NO. 1 COMPRESSION TOP DEAD CENTRE SETTING



1.
caution Turn the crankshaft clockwise.
Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the cylinder No. 1 to the top dead centre of compression. At this time, check that the crankshaft pulley timing mark is in the "T" mark position of the ignition timing indicator of the timing chain case assembly.
2.Put paint marks on both the camshaft sprocket and valve timing chain at the position of camshaft sprocket timing chain mating mark (circular hole).

<<C>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL PREPARATORY OPERATION



1.Insert a precision flat-tipped screwdriver through the service hole of the timing chain case, press up the timing chain tensioner ratchet to unlock, and keep the timing chain tensioner with that state.
note Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.


2.
caution
  • When inserting special tool chain tension release bar (MB992103) into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool (MB992103) beyond its insertion guideline.
  • If unlocking the timing chain tensioner is insufficient, the special tool (MB992103) cannot be inserted to the insertion guideline. Do not insert the special tool (MB992103) forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool (MB992103).
With the timing chain tensioner unlocked, insert special tool chain tension release bar (MB992103) from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (A in the figure).
note With the timing chain tensioner unlocked, insert the special tool (MB992103) along the tension side of the valve timing chain, according to the special tool (MB992103) top shape. The special tool (MB992103) can be inserted smoothly to the position where the special tool (MB992103) insertion guideline aligns with the timing chain case assembly top surface (B in the figure), and the spread timing chain tension side guide can be hold (C in the figure).
3.With the special tool (MB992103) inserted up to the insertion guide line, press the special tool (MB992103) against the inlet side camshaft sprocket and spread and hold the timing chain tension side guide.
4.Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.

5.
caution The valve timing chain may be bitten by other parts. After sagging the valve timing chain, never rotate the crankshaft.
With the timing chain tension side guide spread, hook the special tool (MB992103) over the hexagon part of the camshaft on the exhaust side, and turn the camshaft clockwise to apply slack to the valve timing chain between the camshaft sprockets.

<<D>> CAMSHAFT BEARING FRONT CAP ASSEMBLY REMOVAL


caution Be careful not to drop the camshaft bearing.

Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

<<E>> CAMSHAFT BEARING OIL FEEDING CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING THRUST CAP REMOVAL


caution When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are damaged. Always loosen the mounting bolts in four or five steps.

Loosen the camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<<F>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL



1.Raise slightly the transmission side of the camshaft and camshaft sprocket assembly (exhaust side) by using the slack of the valve timing chain, and remove from the cam bearing.

2.Remove the valve timing chain from the camshaft and camshaft sprocket assembly (exhaust side) toward the timing chain case assembly, and remove the camshaft and camshaft sprocket assembly (exhaust side) toward the transmission.
3.Remove special tool chain tension release bar (MB992103) inserted into the timing chain case assembly inside.

4.
caution The valve timing chain may be bitten by other parts. After removing the camshaft and camshaft sprocket assembly, never rotate the crankshaft.
After removing the camshaft and camshaft sprocket assembly (exhaust side), hang up the valve timing chain with a rope to prevent the valve timing chain from falling into the timing chain case assembly.

<<G>> CAMSHAFT SPROCKET/CAMSHAFT REMOVAL



Hold the hexagon part of the camshaft with a monkey wrench. Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket from the camshaft.

<<H>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL


1.With the hose installed, remove the power steering oil pump assembly from the bracket.
2.Tie the removed power steering oil pump assembly with a string at a position where it will not interfere with the removal and installation of oil control valve.

<<I>> OIL CONTROL VALVE REMOVAL


caution After removal of the oil control valve, be careful to prevent dust from getting into the oil passage in the cylinder head.

INSTALLATION SERVICE POINTS



>>A<< O-RING/OIL CONTROL VALVE INSTALLATION


caution When installing the oil control valve, be careful to avoid damage to the O-ring.
Apply engine oil to the O-ring of the oil control valve and install the oil control valve to the cylinder head.

>>B<< CAMSHAFT/CAMSHAFT SPROCKET INSTALLATION



1.Use a monkey wrench to secure the hexagon part of the camshaft in the same manner as removal.

2.Apply an adequate and minimum amount of engine oil to the positions shown of the camshaft and the camshaft sprocket.
3.Install the camshaft sprocket to the camshaft.
4.Apply an adequate and minimum amount of engine oil to the camshaft sprocket bolt.
5.Tighten the camshaft sprocket mounting bolt to the specified torque.
Tightening torque: 59 ± 5 N·m

>>C<< CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (INLET SIDE) INSTALLATION



1.Align the inlet side paint mark of the valve timing chain which was put at removal with the paint mark of the inlet side camshaft sprocket, and install the camshaft sprocket to the valve timing chain.
2.Install the camshaft and camshaft sprocket assembly (inlet side) to the cylinder head.

>>D<< CAMSHAFT BEARING THRUST CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING OIL FEEDING CAP INSTALLATION



1.Install the camshaft bearing caps to the cylinder head.
note Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.
2.Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps.
Tightening torque: 12 ± 1 N·m

>>E<< CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) INSTALLATION




1.
caution
  • Be careful not to drop the camshaft bearing.
  • When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.
When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap identification mark in the table below. Identification colour of the camshaft bearing is painted in the position shown in the figure.
Camshaft
Camshaft bearing identification colour
Identification mark
Journal diameter mm
1
40.000 - 40.008
Black
2
40.008 - 40.016
None
3
40.016 - 40.024
Green

2.In the same manner as removal, insert the precision flat-tipped screwdriver through the service hole of the timing chain case, press up the ratchet of timing chain tensioner to unlock, and hold the unlocked timing chain tensioner.
note Lightly press down the tail end of the precision flat-tipped screwdriver to press up the tip of the precision flat-tipped screwdriver inserted to the timing chain tensioner to unlock.


3.
caution
  • When inserting special tool chain tension release bar (MB992103) into the timing chain case assembly inside, pay attention to the position of the valve timing chain to avoid damage to the valve timing chain and timing chain tension side guide. Do not insert the special tool (MB992103) beyond its insertion guideline.
  • If unlocking the timing chain tensioner is insufficient, the special tool (MB992103) cannot be inserted to the insertion guideline. Do not insert the special tool (MB992103) forcibly, follow Step 1 again to unlock the timing chain tensioner and insert the special tool (MB992103).
With the timing chain tensioner unlocked, insert special tool chain tension release bar (MB992103) from the timing chain case assembly inside along the tension side of the valve timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (A in the figure).
note With the timing chain tensioner unlocked, insert the special tool (MB992103) along the tension side of the valve timing chain, according to the special tool (MB992103) top shape. The special tool (MB992103) can be inserted smoothly to the position where the special tool (MB992103) insertion guideline aligns with the timing chain case assembly top surface, and the spread timing chain tension side guide can be hold.
4.With the special tool (MB992103) inserted up to the insertion guide line, press the special tool (MB992103) against the inlet side camshaft sprocket (B in the figure) and spread and hold the timing chain tension side guide (C in the figure).
5.Remove the flat-tipped precision screwdriver unlocking the timing chain tensioner.
6.Pull up the camshaft and camshaft sprocket assembly (exhaust side) mounting area of the valve timing chain (D in the figure) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the valve timing chain.

7.
caution When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.
Align the exhaust side paint mark of the valve timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the valve timing chain to the camshaft sprocket.
8.Install the camshaft and camshaft sprocket assembly (exhaust side) to the cylinder head.
9.Remove the special tool (MB992103) inserted into the timing chain case assembly inside.

>>F<< CAMSHAFT BEARING FRONT CAP ASSEMBLY INSTALLATION



1.
caution When the mounting bolts are tightened with the camshaft bearing front cap tilted, the camshaft bearing front cap is damaged. Install the camshaft bearing front cap properly to the cylinder head and camshaft.
Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap mounting bolts to the specified torque in the order shown in the figure (1).
Tightening torque: 17 ± 3 N·m
2.Tighten again the camshaft bearing front cap mounting bolts to the specified torque again in the order shown in the figure (2).
Tightening torque: 30 ± 2 N·m
3.After the camshaft bearing font cap installation, check that the paint markings of the camshaft sprocket and the timing chain and the timing mark of the crankshaft pulley and the "T" mark position of ignition timing indicator are aligned respectively.

>>G<< ROCKER COVER ASSEMBLY INSTALLATION


1.Remove the sealant from the joints between the rocker cover assembly and cylinder head and timing chain case assembly, and degrease the surface where the sealant is applied by white gasoline or the like.

2.
caution Do not apply oil or water to the sealant-applied area or start up the engine within 2 hours after the installation of the rocker cover assembly.
Apply sealant to the joint between the cylinder head and timing chain case assembly as shown in the figure and install the rocker cover assembly to the cylinder head.
Specified sealant: Three bond 1227D or equivalent
note Install the rocker cover assembly within 3 minutes after the application of sealant.

3.Tighten the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 3.0 ± 1.0 N·m
4.Tighten again the rocker cover assembly mounting bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 5.5 ± 0.5 N·m