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REMOVAL AND INSTALLATION
 
 
Pre-removal and Post-installation Operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover (RH) Removal and Installation (Refer to GROUP 51 - Under Cover ).
  • Air Cleaner Assembly Removal and Installation (Refer to GROUP 15 - Air Cleaner ).
Camshaft removal steps
•Ignition coil (Refer to GROUP 16 - Ignition System, Ignition Coil ).
1.Breather hose
2.PCV hose connection
•Control wiring harness connection
>>G<<3.Cylinder head cover assembly
4.Cylinder head cover gasket
<<A>>•No.1 cylinder compression top dead center setting <only at removal>.
•Valve clearance adjustment (Refer to ) <only at installation>.
5.Service hole bolt
<<B>>•Camshaft and camshaft sprocket assembly (exhaust side) removal preparatory operation <only at removal>.
<<C>>>>F<<6.Camshaft bearing front cap assembly
>>E<<7.Camshaft bearing
<<D>>>>D<<8.Camshaft bearing oil feeding cap (exhaust side)
<<D>>>>D<<9.Camshaft bearing cap (exhaust side)
<<D>>>>D<<10.Camshaft bearing cap (exhaust side)
<<D>>>>D<<11.Camshaft bearing thrust cap (exhaust side)
<<E>>>>E<<12.Camshaft and camshaft sprocket assembly (exhaust side)
<<F>>>>B<<13.Exhaust camshaft sprocket
<<F>>>>B<<14.Camshaft (exhaust side)
>>E<<15.Camshaft bearing
<<D>>>>D<<16.Camshaft bearing oil feeding cap (intake side)
<<D>>>>D<<17.Camshaft bearing cap (intake side)
<<D>>>>D<<18.Camshaft bearing cap (intake side)
<<D>>>>D<<19.Camshaft bearing thrust cap (intake side)
>>C<<20.Camshaft and camshaft sprocket assembly (intake side)
<<F>>>>B<<21.Intake V.V.T. sprocket assembly
<<F>>>>B<<22.Camshaft (intake side)
Oil feeder control valve removal steps 
<<G>>>>A<<23.Oil feeder control valve intake
>>A<<24.O-ring

    Required Special Tool:
  • MB992103: Chain Tension Release Bar
 
 
REMOVAL SERVICE POINTS
 
 
<<A>> NO.1 CYLINDER COMPRESSION TOP DEAD CENTER SETTING
1.
cautionNever turn the crankshaft counterclockwise.
Turn the crankshaft clockwise so that the camshaft sprocket timing marks become horizontal to the cylinder head upper surface, and set the No.1 cylinder to the top dead center 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).
 

 
 
<<B>> 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.
noteLightly 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 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 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).
noteWith 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 intake side camshaft sprocket and spread and hold the timing chain tension side guide.
4. Remove the precision flat-tipped screwdriver unlocking the timing chain tensioner.
5.
cautionThe 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.
 

 
 
<<C>> CAMSHAFT BEARING FRONT CAP ASSEMBLY REMOVAL
cautionBe 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.
 

 
 
<<D>> CAMSHAFT BEARING OIL FEEDING CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING THRUST CAP REMOVAL
cautionWhen 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.
 

 
 
<<E>> CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (EXHAUST SIDE) REMOVAL
1. Raise slightly the front transaxle 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 front transaxle.
3. Remove special tool MB992103 inserted into the timing chain case assembly inside.

4.
cautionThe 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.
 

 
 
<<F>> SPROCKET/CAMSHAFT REMOVAL
Hold the hexagon part of the camshaft with a monkey wrench. Loosen the sprocket mounting bolt and remove the sprocket from the camshaft.
 

 
 
<<G>> OIL FEEDER CONTROL VALVE REMOVAL
cautionAfter removal of the oil feeder control valve, be careful to prevent dust from getting into the oil passage in the cylinder head.
 
 
 
 
INSTALLATION SERVICE POINTS
 
 
>>A<< O-RING/OIL FEEDER CONTROL VALVE INSTALLATION
cautionWhen installing the oil feeder control valve, be careful to avoid damage to the O-ring.
Apply engine oil to the O-ring of the oil feeder control valve and install the oil feeder control valve to the cylinder head.
 
 
 
>>B<< 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 intake V.V.T. sprocket assembly.
3. Install the sprocket to the camshaft.
4. Apply an adequate and minimum amount of engine oil to the intake V.V.T. sprocket bolt.
5. Tighten the sprocket bolt to the specified torque.
Tightening torque: 59 ± 5 N·m (44 ± 3 ft-lb)
 

 
 
>>C<< CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY (INTAKE SIDE) INSTALLATION
1. Align the intake side paint mark of the valve timing chain which was put at removal with the paint mark of the intake side camshaft sprocket, and install the camshaft sprocket to the valve timing chain.
2. Install the camshaft and camshaft sprocket assembly (intake 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.
noteBecause 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 intake 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 (106 ± 8 in-lb)
 

 
 
>>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 assembly identification mark in the table below. The camshaft bearing identification mark is stamped at the position shown in the figure.
 
Camshaft bearing front cap assemblyCamshaft bearing identification mark
Identification markJournal diameter mm (in)
140.000 - 40.008
(1.5749 - 1.5751)
1
240.008 - 40.016
(1.5752 - 1.5754)
2
340.016 - 40.024
(1.5755 - 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.
noteLightly 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 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 2 again to unlock the timing chain tensioner and insert the special tool MB992103.
With the timing chain tensioner unlocked, insert special tool 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).
noteWith 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 too 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 (B in the figure) and spread and hold the timing chain tension side guide (C in the figure).
5. Remove the precision flat-tipped 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.
cautionWhen 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.
cautionWhen 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 to the specified torque in the order shown in the figure (1).
Tightening torque: 17 ± 3 N·m (13 ± 2 ft-lb)
2. Tighten the camshaft bearing front cap to the specified torque again in the order shown in the figure (2).
Tightening torque: 30 ± 2 N·m (22 ± 1 ft-lb)
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<< CYLINDER HEAD COVER ASSEMBLY INSTALLATION
1.
cautionFollow the steps below to degrease the sealant application surface.
  • Before degreasing, make sure that the sealant application surface is free of dust, oil, or foreign materials.
  • Wipe the sealant application surface with a dry paper towel.
  • By using detergent for aluminum, degrease the sealant application surface by spray cleaning.
  • Wipe detergent thoroughly with a dry paper towel. Do not touch the sealant application surface with your fingers, as the fingerprints adhering to the sealant surface affect the sealing.
Remove the sealant from the cylinder head cover assembly and the matching area of the cylinder head assembly and the timing chain case assembly, and degrease the surface where the sealant is applied.
2. Apply specified sealant to the matching area of the cylinder head assembly and the timing chain case assembly as shown, and install the cylinder head cover assembly to the cylinder head assembly.
Specified sealant: ThreeBond 1217G or equivalent
noteInstall the cylinder head cover assembly immediately after the application of sealant.
3. Tighten the cylinder head cover assembly mounting bolts to the specified torque in the order of the numbers shown in the illustration.
Tightening torque: 3.0 ± 1.0 N·m (27 ± 8 in-lb)
4.
cautionAfter the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Tighten again the cylinder head 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)