REMOVAL AND INSTALLATION


caution *Remove and assemble the marked parts in each cylinder unit.

<LEFT BANK>






Camshaft removal steps


·
Engine cover (Refer to GROUP 16 - Ignition System, Ignition Coil <6B3> ).


·
Timing belt (Refer to ).


·
Thermostat housing (Refer to GROUP 14 - Water Hose and Water Pipe <6B3 (Vehicles without EGR)> ).


·
Thermostat housing (Refer to GROUP 14 - Water Hose and Water Pipe <6B3 (Vehicles with EGR)> ).


1.
Engine oil level gauge


2.
O-ring


3.
Blow-by hose connection


4.
PCV hose connection


5.
Ignition coil connector


6.
Ignition coil

>>I<<
7.
Rocker cover


8.
Rocker cover gasket
<<A>>
>>H<<
9.
Rocker arm, shaft and lash adjuster assembly (exhaust side)
<<A>>
>>H<<
10.
Rocker arm and shaft assembly (inlet side)


11.
Oil pipe


12.
Gasket


13.
Harness bracket


14.
Camshaft position sensor connector


15.
Camshaft position sensor


16.
O-ring


17.
Camshaft position sensor support


18.
Camshaft position sensor support gasket


19.
Camshaft position sensing cylinder
<<B>>
>>E<<
20.
Camshaft sprocket


21.
Camshaft
<<C>>
>>D<<
22.
Camshaft oil seal



Valve stem seal removal steps


·
Engine cover (Refer to GROUP 16 - Ignition System, Ignition Coil <6B3> ).


1.
Engine oil level gauge


2.
O-ring


3.
Blow-by hose connection


4.
PCV hose connection


5.
Ignition coil connector


6.
Ignition coil

>>I<<
7.
Rocker cover


8.
Rocker cover gasket
<<A>>
>>H<<
9.
Rocker arm, shaft and lash adjuster assembly (exhaust side)
<<A>>
>>H<<
10.
Rocker arm and shaft assembly (inlet side)


·
Spark plug (Refer to GROUP 16 - Ignition System, Ignition Coil <6B3> ).


23.
Engine hanger
<<E>>
>>C<<
24.
Valve spring retainer lock


25.
Valve spring retainer

>>B<<
26.
Valve spring

>>A<<
27.
Valve stem seal


28.
Valve spring seat

<RIGHT BANK>






Camshaft removal steps


·
Air intake plenum (Refer to GROUP 15 - Air Intake Plenum <6B3 (Vehicles without EGR)> ).


·
Air intake plenum (Refer to GROUP 15 - Air Intake Plenum <6B3 (Vehicles with EGR)> ).


·
Timing belt (Refer to ).


·
Thermostat housing (Refer to GROUP 14 - Water Hose and Water Pipe <6B3 (Vehicles without EGR)> ).


·
Thermostat housing (Refer to GROUP 14 - Water Hose and Water Pipe <6B3 (Vehicles with EGR)> ).


1.
Blow-by hose connection


2.
Breather hose connection


3.
Ignition coil connector


4.
Ignition coil

>>I<<
5.
Rocker cover


6.
Rocker cover gasket
<<A>>
>>H<<
7.
Rocker arm, shaft and lash adjuster assembly (exhaust side)
<<A>>
>>H<<
8.
Rocker arm and shaft assembly (inlet side)


9.
Engine oil control valve connector


10.
Engine oil pressure switch connector

>>G<<
11.
Engine oil control valve

>>G<<
12.
O-ring

>>F<<
13.
Engine oil pressure switch


14.
Plug


15.
Engine oil control valve filter


16.
Engine oil control valve housing


17.
Engine oil control valve housing gasket
<<B>>
>>E<<
18.
Camshaft sprocket


·
Engine-ECU (Refer to GROUP 13C - Engine-ECU ).


·
Air cleaner bracket (Refer to GROUP 15 - Air Cleaner <6B3> ).


19.
Camshaft
<<C>>
>>D<<
20.
Camshaft oil seal



Valve stem seal removal steps


·
Air intake plenum (Refer to GROUP 15 - Air Intake Plenum <6B3 (Vehicles without EGR)> ).


·
Air intake plenum (Refer to GROUP 15 - Air Intake Plenum <6B3 (Vehicles with EGR)> ).


·
Timing belt (Refer to ).


1.
Blow-by hose connection


2.
Breather hose connection


3.
Ignition coil connector


4.
Ignition coil

>>I<<
5.
Rocker cover


6.
Rocker cover gasket
<<A>>
>>H<<
7.
Rocker arm, shaft and lash adjuster assembly (exhaust side)
<<A>>
>>H<<
8.
Rocker arm and shaft assembly (inlet side)


·
Spark plug (Refer to GROUP 16 - Ignition System, Ignition Coil <6B3> ).
<<D>>

·
Power steering oil pump (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).
<<E>>
>>C<<
21.
Valve spring retainer lock


22.
Valve spring retainer

>>B<<
23.
Valve spring

>>A<<
24.
Valve stem seal


25.
Valve spring seat

REMOVAL SERVICE POINTS



<<A>> ROCKER ARM, SHAFT AND LASH ADJUSTER ASSEMBLY (EXHAUST SIDE)/ROCKER ARM AND SHAFT ASSEMBLY (INLET SIDE) REMOVAL



1.Install special tool auto-lash adjuster holder (MD998443) as shown in the illustration so that the lash adjusters will not fall out.
2.
caution Never disassemble the rocker arm and shaft assembly.
Loosen the rocker arm and shaft assembly mounting bolts, and then remove the rocker arm and shaft assembly with the mounting bolts still attached.

<<B>> CAMSHAFT SPROCKET REMOVAL



Use the following special tools to remove the camshaft sprocket.

  • Front hub and flange yoke holder (MB990767)
  • Pin (MD998719)

<<C>> CAMSHAFT OIL SEAL REMOVAL


1.Make a notch in the camshaft oil seal lip section with a knife, etc.

2.
caution Be careful not to damage the camshaft and the cylinder head.
Cover the end of a flat-tipped screwdriver with a shop towel and insert into the notched section of the camshaft oil seal, and pry out the camshaft oil seal to remove it.

<<D>> POWER STEERING OIL PUMP REMOVAL


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

<<E>> VALVE SPRING RETAINER LOCK REMOVAL


caution When removing valve spring retainer lock, leave the piston of each 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.


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

note Installation position of special tool (MD998772) is different between exhaust side and inlet side.

INSTALLATION SERVICE POINTS



>>A<< VALVE STEM SEAL INSTALLATION



1.
caution Valve stem seal for intake valves and for exhaust valves are different. Be sure to install the correct ones.

  • Valve stem seal identification colour.

    • Intake: GREY
      Exhaust: GREY GREEN
Apply an adequate and minimum amount of engine oil to the valve stem seal.

2.
caution
  • Valve stem seal cannot be reused.
  • Special tool valve stem seal installer (MB992182) 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 (MB992182) to fill a new valve stem seal in the valve guide using the valve stem area as a guide.

>>B<< VALVE SPRING INSTALLATION



Install the valve spring with its identification colour painted end facing the locker arm.
Identification colour
    Intake: Red
    Exhaust: Green

>>C<< VALVE SPRING RETAINER LOCK INSTALLATION




Use special tool valve spring compressor (MD998772) to compress the valve spring in the same manner as removal, and install the valve spring retainer locks.

>>D<< CAMSHAFT OIL SEAL INSTALLATION


1.Apply an adequate and minimum amount of engine oil to the camshaft oil seal lip.


2.Use the following special tools to press-fit the camshaft oil seal.

  • Camshaft oil seal installer (MD998713)
  • Camshaft oil seal adapter installer (MD998777)

>>E<< CAMSHAFT SPROCKET INSTALLATION



1.Use the following special tools in the same way as during removal to install the camshaft sprocket.

  • Front hub and flange yoke holder (MB990767)
  • Pin (MD998719)
2.Tighten the camshaft sprocket mounting bolt to the specified torque.
Tightening torque: 90 ± 10 N·m

>>F<< ENGINE OIL PRESSURE SWITCH INSTALLATION



Apply the specified sealant to the thread of the engine oil pressure switch.
Specified Sealant: Three bond 1104, 1215, 1212 or equivalent

>>G<< O-RING/ENGINE OIL CONTROL VALVE INSTALLATION



1.
caution
  • Never re-use the O-ring.
  • Before installing O-ring, wind sealing tape around the oil passages cut-out area of engine oil control valve, to prevent damage. If the O-ring is damaged, it can cause an oil leak.
Apply an adequate and minimum amount of engine oil to the O-ring and then install it to the engine oil control valve.
2.Install the engine oil control valve to the cylinder head.
3.Tighten the engine oil control valve.
Tightening torque: 11 ± 1 N·m

>>H<< ROCKER ARM AND SHAFT ASSEMBLY (INLET SIDE)/ROCKER ARM, SHAFT AND LASH ADJUSTER ASSEMBLY (EXHAUST SIDE) INSTALLATION




1.Install the inlet side rocker arm and shaft assembly so that the Φ5.5 mm holes of rocker arm shaft face the cylinder head side.
2.Tighten the inlet side rocker arm shaft mounting bolts to the specified torque.
Tightening torque: 31 ± 3 N·m
3.Install the exhaust side rocker arm, shaft and lash adjuster assembly so that the notch of rocker arm shaft is located as shown in the figure.
4.Check that the identification mark of exhaust side rocker shaft cap is located as shown in the figure.
5.Tighten the exhaust side rocker arm shaft mounting bolts to the specified torque.
Tightening torque: 13 ± 1 N·m

6.Remove special tool auto-lash adjuster holder (MD998443).

>>I<< ROCKER COVER INSTALLATION



Tighten the rocker cover mounting bolts to the specified torque in order of the numbers shown in the illustration.
Tightening torque: 8.3 ± 1.0 N·m