REMOVAL AND INSTALLATION

Removal steps 1. Engine cover >>N<< 2. Oil feeder control valve · Ignition coil (Refer to GROUP 16, Ignition System - Ignition Coil ). 3. Control wiring harness clamp 4. Rocker cover PCV hose connection 5. Vacuum hose connection >>M<< 6. Rocker cover assembly 7. Spark plug guide oil seal 8. Rocker cover gasket 9. Noise condenser 10. Camshaft position sensor connector connection 11. Air intake pipe bracket >>L<< 12. Camshaft position sensor support >>K<< 13. Camshaft position sensing cylinder <<A>> 14. Camshaft sprocket cap 15. Washer <<B>> >>J<< 16. Camshaft sprocket (inlet side) >>H<< 17. Camshaft oil seal >>F<< 18. Camshaft bearing cap, front >>F<< 19. Camshaft bearing cap, rear right >>F<< 20. Camshaft bearing cap, No.2 >>F<< 21. Camshaft bearing cap, No.5 >>F<< 22. Camshaft bearing cap, No.3 >>F<< 23. Camshaft bearing cap, No.4 >>E<< 24. Inlet camshaft <<B>> >>I<< 25. Camshaft sprocket (exhaust side) >>H<< 26. Camshaft oil seal >>F<< 27. Camshaft bearing cap, front >>F<< 28. Camshaft bearing cap, rear left 29. Waste gate solenoid valve connector connection >>G<< 30. Cylinder head camshaft end seal >>F<< 31. Camshaft bearing cap, No.2 >>F<< 32. Camshaft bearing cap, No.5 >>F<< 33. Camshaft bearing cap, No.3 >>F<< 34. Camshaft bearing cap, No.4 >>E<< 35. Exhaust camshaft 36. Rocker arm >>D<< 37. Rocker arm lash adjuster <<C>> >>C<< 38. Valve spring retainer lock 39. Valve spring retainer >>B<< 40. Valve spring >>A<< 41. Inlet valve stem seal >>A<< 42. Exhaust valve stem seal

LUBRICATION AND SEALING POINTS

Remove the camshaft sprocket cap with a 8-mm hexagonal wrench.

1.Hold the hexagon part of the camshaft with a wrench. 2.Loosen the camshaft sprocket mounting bolt and remove the camshaft sprocket.

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

1.Check the valve stem seal colour to identify the inlet side or exhaust side. 2.Apply a small amount of engine oil to the valve stem seal.

3. caution Do not re-use the valve stem seal. Special tool valve stem seal installer (MB991671) must be used to install the valve stem seal. Improper installation could result in oil leaking past the valve guide. Use special tool valve stem seal installer (MB991671) to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

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

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

caution If the rocker arm lash adjuster is reused, always clean and check it before installation. (Refer to GROUP 11F, Rocker Arms and Camshaft ).

3. caution Do not install wrong camshaft at the side of inlet or exhaust. The inlet camshaft has a slit at the rear surface. Install the camshaft to the engine cylinder head.

1.Set the dowel pin of the camshaft to the position as shown in the illustration.

2.Camshaft bearing caps (No.2 to 5) are identical. To avoid confusion (bearing cap No. and inlet/exhaust side), confirm each identification mark and face the front mark towards the direction shown before installing them. Identification mark (engraved on the front and bearing caps No.2 - 5) I: Inlet side E: Exhaust side

3.Apply sealant to the positions (8 areas) of the upper side of the cylinder head as shown in the illustration. Specified sealant: ThreeBond 1212D or equivalent note Install the camshaft bearing caps, rear and camshaft bearing caps immediately after applying sealant. 4.Check the identification marks on the camshaft bearing cap, front so that inlet side and exhaust side cannot be mistaken in the same way as that of bearing caps No.2 - 5. 5. 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. Tighten the bearing cap mounting bolts increasing the pressure in 2 to 3 times and finally tighten to the specified torque. Tightening torque: 25 ± 1 N·m <Camshaft bearing cap, front and rear> 11 ± 1 N·m <Camshaft bearing cap No.2 - 5> 6.Ensure that the rocker arms are installed properly. note Remove an excess of sealant completely.

Use special tool circular packing installer (MD998762) to press-fit the cylinder head camshaft end seal as shown.

1.Apply engine oil to the entire inner diameter of the oil seal lip. 2.Use special tool camshaft oil seal installer (MD998713) to press-fit the oil seal as shown.

1.Hold the hexagon part of the camshaft with a wrench. 2.Install the camshaft sprocket and tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 88 ± 10 N·m

1.Apply engine oil to the tip of the camshaft and the camshaft installation side of the camshaft sprocket. 2.Align the dowel pin hole of the camshaft sprocket with the dowel pin of the camshaft, and install the camshaft sprocket to the camshaft. 3.While holding the hexagonal area of the camshaft with a wrench, check that the camshaft sprocket does not turn. note This is necessary, because you cannot confirm that the camshaft dowel pin is inserted into the pin hole.

4.Apply the engine oil to the threads and the face of the camshaft sprocket mounting bolt. Then fix the camshaft with a wrench in the same way as removal and tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 55 ± 5 N·m

2.Install the camshaft position sensing cylinder as shown, and tighten the camshaft position sensing cylinder mounting bolt to the specified torque. Tightening torque: 22 ± 4 N·m

2.Apply the sealant to the camshaft position sensor support flange in a continuous bead as shown in the illustration. Specified sealant: ThreeBond 1207F note Install the camshaft position sensor support immediately after applying sealant. 3.Install the camshaft position sensor support to the cylinder head. 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. Tighten the camshaft position sensor support mounting bolts to the specified torque. Tightening torque: 14 ± 1 N·m

1.Tighten the each bolt to 5.0 ± 1.0 N·m in the order (1-14) shown. 2.After tightening of step 1, tighten the each bolt to 7.0 ± 1.0 N·m in the order (1-10) shown.