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10) Remove oil level gauge guide. (LH side only)
11) Remove spark plug cord.
12) Remove rocker cover and gasket.
13) Loosen intake camshaft cap bolts equally, a little at a time in alphabetical sequence shown in figure.
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1) Remove V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
2) Remove crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, REMOVAL, Crankshaft Pulley.>
3) Remove belt cover. <Ref. to ME(DOHC TURBO)-47, REMOVAL, Belt Cover.>
4) Remove timing belt assembly. <Ref. to ME(DOHC TURBO)-48, REMOVAL, Timing Belt Assembly.>
5) Remove camshaft sprocket. <Ref. to ME(DOHC TURBO)-56, REMOVAL, Camshaft Sprocket.>
6) Remove crankshaft sprocket. <Ref. to ME(DOHC TURBO)-57, REMOVAL, Crankshaft Sprocket.>
7) Remove left-hand belt cover No. 2.
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14) Remove camshaft caps and intake camshaft.
15) Loosen exhaust camshaft cap bolts equally, a little at a time in alphabetical sequence shown in figure.
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8) Remove right-hand belt cover No.2.
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16) Remove camshaft caps and exhaust camshaft.
CAUTION:
Arrange camshaft caps in order so that they
can be installed in their original positions.
17) Similarly, remove right-hand camshafts and related parts.
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9) Remove tensioner bracket.
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Fluid packing:
THREE BOND 1215 or equivalent
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1) Camshaft installation Apply engine oil to cylinder head at camshaft bear-ing location before installing camshaft. Install cam-shaft so that each valves is close to or in contact with "base circle" of cam lobe.
CAUTION:
• When camshafts are positioned as shown in figure, camshafts need to be rotated at a minimum to align with timing belt during installation.
• Right-hand camshaft need not be rotated when set at position shown in figure. Left-hand intake camshaft: Rotate 80° clock-wise. Left-hand exhaust camshaft: Rotate 45° counterclockwise.
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(2) Apply engine oil to cap bearing surface and install cap on camshaft as shown by identification mark (A).
(3) Gradually tighten cap in at least two stages in alphabetical sequence shown in figure, and then tighten to specified torque.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
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(4) Similarly, tighten cap on exhaust side. After tightening cap, ensure camshaft rotates only slightly while holding it at "base" circle.
Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
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A Left side cylinder head
? Right side cylinder head
(a) Intake camshaft
(b) Exhaust camshaft
2) Camshaft cap installation
(1) Apply fluid packing sparingly to cap mating surface.
CAUTION:
Do not apply fluid packing excessively. Failure
to do so may cause excess packing to come
out and flow toward oil seal, resulting in oil
leaks.
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3) Camshaft oil seal installation Apply grease to new oil seal lips and press onto front end of camshaft by using ST1 and ST2.
CAUTION:
Use a new oil seal.
ST1 499587600 OIL SEAL INSTALLER ST2 499597200 OIL SEAL GUIDE
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7) Install right-hand belt cover No. 2.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
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8) Install left-hand belt cover No. 2.
Tightening torque:
5 Nm (0.5 kgf-m, 3.6 ft-lb)
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4) Rocker cover installation
(1) Install gasket on rocker cover. Install peripheral gasket and ignition coil gasket.
(2) Apply fluid packing to four front open edges of peripheral gasket.
Fluid packing:
THREE BOND 1215 or equivalent
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9) Install tensioner bracket.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
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(3) Install rocker cover on cylinder head. Ensure gasket is properly positioned during installation.
5) Install spark plug cord.
6) Similarly, install parts on right-hand side.
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10) Install crankshaft ME(DOHC TURBO)-56, shaft Sprocket.>
11) Install camshaft ME(DOHC TURBO)-56, shaft Sprocket.>
12) Install timing belt ME(DOHC TURBO)-49, Belt Assembly.>
13) Install belt cover.
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sprocket. <Ref. to INSTALLATION, Cam-sprockets. <Ref. to INSTALLATION, Cam-assembly. <Ref. to INSTALLATION, Timing
<Ref. to ME(DOHC
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TURBO)-47, INSTALLATION, Belt Cover.>
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14) Install crankshaft pulley. <Ref. to ME(DOHC TURBO)-46, INSTALLATION, Crankshaft Pulley.>
15) Install V-belt. <Ref. to ME(DOHC TURBO)-44, INSTALLATION, V-belt.>
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Tightening torque:
20 Nm (2.0 kgf-m, 14.5 ft-lb)
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1) Measure the bend, and repair or replace if necessary.
Limit:
0.020 mm (0.0008 in)
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CAUTION:
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the widest point of the plastigauge on each journal. If the oil clearance exceeds the limit, replace the camshaft. If necessary, replace the camshaft caps and cylinder head as a set.
Standard:
0.037 — 0.072 mm (0.0015 — 0.0028 in)
Limit:
0.10 mm (0.0039 in)
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2) Check journal for damage and wear. Replace if faulty.
3) Measure outside diameter of camshaft journal. If the journal diameter is not as specified, check the oil clearance.
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37.946 — 37.963 (1.4939— 1.4946 in)
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29.946 — 29.963 (1.1790 —1.1796 in)
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4) Measurement of the camshaft journal oil clearance
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head. (Without installing valve rocker.)
(3) Place plastigauge across each of the camshaft journals.
(4) Gradually tighten cap in at least two stages in alphabetical sequence shown in figure, and then tighten to specified torque.
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(7) Completely remove the plastigauge. 5) Check cam face condition; remove minor faults by grinding with oil stone. Measure the cam height H; replace if the limit has been exceeded.
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Cam height: H Standard: Intake:
44.75 — 44.85 mm (1.7618 Exhaust:
44.60 — 44.70 mm (1.7559
Limit: Intake:
44.65 mm (1.7579 in) Exhaust:
44.50 mm (1.7520 in)
Cam base circle diameter A: 37.0 mm (1.457 in)
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6) Measure the thrust clearance of camshaft with dial gauge. If the clearance exceeds the limit, replace caps and cylinder head as a set. If necessary replace camshaft.
Standard:
0.015 — 0.070 mm (0.0006 — 0.0028 in)
Limit:
0.1 mm (0.004 in)
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