Remove the air filter assembly.
Remove ignition coils.
Remove the top timing belt cover.
Remove the timing belt.
Removing
After aligning the relative position of the radiator hose and clamp, disconnect the upper radiator hose.
Fix the camshaft sprocket against rotation using a special fork holder and special bolts or using a camshaft hexagon wrench (the cylinder head cover must be removed).
Loosen the camshaft sprocket bolt.
Note. When disassembling the valve mechanism and loosening the valves, use the special tool MD 998772.
Note. When disassembling the valve mechanism and loosening the valves, use the special tool MD 998772.
Installing the valve stem seal
Apply a thin coat of engine oil to the lip of the oil cap. Install the valve stem seal by hand so that its bottom touches the top surface of the guide bush.
Slowly press on the oil seal vertically until the special tool stops against the valve spring plate installed in the cylinder head.
Installing the valve spring
Install the valve spring with the blue painted end A up as shown.
Installation of crackers
Using the special tools, install the crackers as shown in the picture.
Installation of camshafts
Apply a small amount of engine oil to the cams and camshaft bearing journals.
Install the camshaft to the cylinder head.
Attention! Be careful not to damage the camshafts when installing.
Do not mix up camshafts. At the rear end of the exhaust camshaft there is a hole for the camshaft position sensor rotor mounting bolt.
Position the camshafts in the cylinder head so that their guide pins are in the position shown in the figure.
Since some bearing caps have the same diameter, in order to avoid confusion, check that the identification marks match before installing the caps.
Identification marks (printed on the front cover and bearing caps #2 - #5).
- Inlet valve side: I.
- Exhaust side: E.
Apply sealant in a continuous bead about 3 mm in diameter to the mating surface of the cylinder head at the 6 points shown in the figure.
Install the camshaft bearing cap gasket to the cylinder head.
Install the camshaft bearing cap assembly to the cylinder head until the sealant dries and hardens.
Install the camshaft bearing cap bolts and gradually tighten the bolts in two or three steps in the order shown in the figure. Tighten the bolts to rated torque in the final tightening sequence.
Installing the camshaft oil seal
Apply a small amount of engine oil to the lip of the oil seal around its entire circumference.
Using a special mandrel, press in the oil seal as shown in the figure.
Establish an axis of yokes in gathering.
Camshaft sprocket installation
Fix the camshaft sprocket against rotation using a special fork holder and special bolts or using a camshaft hexagon wrench (the cylinder head cover must be removed).
Tightening torque: 89±9 Nm.
Installing the camshaft position sensor support
Before installation, apply the specified sealant in a continuous bead of approximately 3 mm in diameter to the camshaft position sensor support.
Installing the Camshaft Position Sensor Rotor
Make sure the #1 piston is at top dead center (TDC) (exhaust camshaft pin points vertically upwards).
Note. The camshaft can rotate under the action of the exhaust valve springs.
Install the camshaft position sensor rotor so that the white paint mark is located as shown in the figure.
When connecting the upper radiator hose, put the hose on the branch pipe until it stops against the protrusion of the branch pipe, then tighten the clamp.
The hose clamp should always be installed in the position in which the clamp was installed when removed. Therefore, before installing the clamp, align the alignment marks on the hose clamp and the radiator hose, then connect it.
Apply a bead of sealant to the four locations shown in the figure and install the cylinder head cover within 15 minutes.
Install the coolant inlet pipe and thermostat housing assembly.
Install the timing belt.
Install the timing belt top cover.
Install the ignition coils.
Install the air filter assembly.
Adjust the timing belt tension.
Fill with coolant and engine oil.