REMOVAL AND INSTALLATION

Camshaft removal steps 1. Breather hose connection 2. PCV hose connection 3. Power steering fluid pressure switch connector connection 4. Intake oil feeder control valve connector connection 5. Exhaust oil feeder control valve connector connection 6. Control harness connection <<A>> >>G<< 7. Rocker cover assembly 8. Rocker cover gasket <<B>> · Cylinder No. 1 compression top dead center setting (only at removal) · Valve clearance adjustment (Refer to ). (only at installation) 9. Timing chain upper guide 10. Service hole bolt <<C>> · Camshaft and camshaft sprocket assembly (exhaust side) removal preparatory operation (only at removal) <<D>> >>F<< 11. Front camshaft bearing cap assembly >>E<< 12. Camshaft bearing <<E>> >>D<< 13. Oil feeding camshaft bearing cap (exhaust side) <<E>> >>D<< 14. Camshaft bearing cap (exhaust side) <<E>> >>D<< 15. Camshaft bearing cap (exhaust side) <<E>> >>D<< 16. Thrust camshaft bearing cap (exhaust side) <<F>> >>E<< 17. Camshaft and camshaft sprocket assembly (exhaust side) <<G>> >>B<< 18. Camshaft sprocket bolt >>B<< 19. Camshaft sprocket (exhaust side) >>B<< 20. Camshaft (exhaust side) >>E<< 21. Camshaft bearing <<E>> >>D<< 22. Oil feeding camshaft bearing cap (intake side) <<E>> >>D<< 23. Camshaft bearing cap (intake side) <<E>> >>D<< 24. Camshaft bearing cap (intake side) <<E>> >>D<< 25. Thrust camshaft bearing cap (intake side) >>C<< 26. Camshaft and camshaft sprocket assembly (intake side) <<G>> >>B<< 27. Camshaft sprocket bolt >>B<< 28. Camshaft sprocket (intake side) >>B<< 29. Camshaft (intake side) Intake oil feeder control valve removal steps 4. Intake oil feeder control valve connector connection · Drive belt (Refer to ) <<H>> 30. Power steering oil pump assembly <<I>> >>A<< 31. Intake oil feeder control valve >>A<< 32. O-ring Exhaust oil feeder control valve removal steps 5. Exhaust oil feeder control valve connector connection 33. Exhaust oil feeder control valve heat protector <<I>> >>A<< 34. Exhaust oil feeder control valve >>A<< 35. O-ring

• MB992103: Chain Tension Release Bar
  

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

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 center of compression. At this time, check that the crankshaft pulley timing mark is in the 0-degree position of the ignition timing indicator of the timing chain case assembly. 2.Put paint marks on both the camshaft sprocket and timing chain at the position of camshaft sprocket timing chain mating mark (circular hole).

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 MB992103 into the timing chain case assembly inside, pay attention to the position of the timing chain to avoid damage to the 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 MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (Figure A). note With the timing chain tensioner unlocked, insert the special tool MB992103 along the tension side of the 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 guide line aligns with the timing chain case assembly top surface (Figure B), and the spread timing chain tension side guide can be held (Figure C). 3.With the special tool MB992103 inserted up to the insertion guide line, press the special tool against the intake 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 timing chain may snag on by other parts. After sagging the 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 timing chain between the camshaft sprockets.

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

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

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

2.Remove the 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 transaxle. 3.Remove special tool MB992103 inserted into the timing chain case assembly.

4. caution The timing chain may snag on 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 timing chain with a rope to prevent the timing chain from falling into the timing chain case assembly.

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

2.an adequate and minimum amount of engine oil to the outer of the camshaft edge and the entire insertion area around camshaft sprocket assembly. 3.Set the knock pin hole of camshaft sprocket assembly to the right overhead position, and slowly insert it into the camshaft assembly to the specified position. 4.Install the camshaft sprocket to the camshaft. 5.Apply an adequate and minimum amount of engine oil to the thread of the camshaft sprocket bolt and the lower area of the flange.

6.Clamp the hexagon of the camshaft and fix it in the same manner as removal. 7.Tighten the camshaft sprocket bolt to the specified torque. Tightening torque: 85 ± 5 N·m (63 ± 4 ft-lb)

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

1.Install the camshaft bearing caps to the cylinder heads. note Because the thrust camshaft bearing cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation. 2.Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps. Tightening torque: 12 ± 1 N·m (107 ± 8 in-lb)

1. caution Be careful not to drop the camshaft bearing. When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure. Front camshaft bearing cap Camshaft bearing identification mark Identification mark Journal diameter mm (in) 1 40.000 - 40.008 (1.5748 - 1.5751) 1 2 40.008 - 40.016 (1.5751 - 1.5754) 2 3 40.016 - 40.024 (1.5754 - 1.5757) 3

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 MB992103 into the timing chain case assembly, pay attention to the position of the timing chain to avoid damage to the 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 2 again to unlock the timing chain tensioner and insert the special tool MB992103. With the timing chain tensioner unlocked, insert special tool MB992103 inside the timing chain case assembly along the tension side of the timing chain until the insertion guide line aligns with the upper surface of the timing chain case assembly (Figure A). note With the timing chain tensioner unlocked, insert the special tool MB992103 along the tension side of the 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 intake side camshaft sprocket (Figure B) and spread and hold the timing chain tension side guide (Figure C). 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 timing chain (Figure D) to provide allowance for easy installation of the camshaft and camshaft sprocket assembly (exhaust side) to the 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 timing chain which was put at removal with the paint mark of the exhaust side camshaft sprocket, and install the 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 inserted into the timing chain case assembly inside.

1. caution When the mounting bolts are tightened with the front camshaft bearing cap tilted, the front camshaft bearing cap is damaged. Install the front camshaft bearing cap properly to the cylinder head and camshaft. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the camshaft bearing front cap to the specified torque in the order of the figure (1). Tightening torque: 17 ± 3 N·m (13 ± 2 ft-lb) 2.Tighten the front camshaft bearing cap again to the specified torque in the order of the figure (2). Tightening torque: 30 ± 2 N·m (23 ± 1 ft-lb) 3.After installing the front camshaft bearing cap, check that the paint marks of camshaft sprocket and of timing chain, the timing mark of crankshaft pulley, and the T-mark position of ignition timing indicator are aligned correctly.

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. 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 1217G or equivalent note Install the rocker cover assembly immediately 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 (27 ± 8 in-lb) 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 (49 ± 4 in-lb)