Installation Procedure
- NOTE:
Second technician is required.
Hold tension to the camshaft timing chain (1) with 2 hands.
- NOTE:
Second technician is required.
Set the crankshaft in direction of engine rotation to 60 degrees (a) before TDC of cylinder 1. Use the EN-45059 angle meter and the crankshaft balancer absorber bolt (1).
- Lay the camshaft timing chain between the timing chain guides.
- Clean the sealing surface from the camshaft bearing rear cap and the cylinder head.
Coat the exhaust camshaft (5) and the exhaust camshaft bearing caps (4) with MoS 2 lubricating paste or engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers .
- Exhaust Camshaft(5) - Install
- Ensure that the camshaft notch (3) at the front of the camshaft is in the 12 O ' clock position before installing the camshaft bearing caps.
- Install the 4 exhaust camshaft bearing caps (4) to the cylinder head.
- Install the exhaust bearing front cap (1) to the cylinder head.
- Loosely install the 10 exhaust camshaft bearing cap bolts (2).
- CAUTION:
Refer to Fastener Caution .
Tighten the 10 exhaust camshaft bearing cap bolts (1) to 9 N.m (80 lb in), working from inside to outside in a spiral.
Clean The cylinder head and the exhaust camshaft rear bearing cap surfaces from dirt, grease and sealant remains.
- Apply sealing compound (2) to the cylinder head (1). The thickness of the sealing should be thin. Refer to Adhesives, Fluids, Lubricants, and Sealers .
Camshaft Bearing Rear Cap(2) - Install
- Install the 4 camshaft bearing rear cap bolts (1) and tighten to 9 N.m (80 lb in).
Install the exhaust camshaft position actuator adjuster (2).
- Mind the camshaft pin (1), the exhaust camshaft position actuator adjuster does fit in only one position.
- Install and hand tighten a NEW exhaust camshaft position actuator adjuster bolt (3).
Install the EN-51148 holding tool (1) to camshafts and to the cylinder head.
- Turn the camshafts at the camshaft position actuator adjuster bolts (5, 6) until the EN-51148 holding tool fits.
- Tighten the bolt (3) in the middle.
- Tighten the 2 outer bolts (2, 4).
- Tighten the exhaust camshaft position actuator adjuster bolt (5) in 2 passes:
- First pass to 65 N.m (48 lb ft).
- Final pass to an additional 120 - 135 degrees, using the EN-45059 meter.
- NOTE:
Second technician is required.
Hold tension to the camshaft timing chain (1) with 2 hands.
- NOTE:
Second technician is required.
Adjust the engine to cylinder 1 top dead center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (2, 3) line up. Rotate at the crankshaft balancer absorber bolt (1).
Install the camshaft timing chain to the camshaft position actuator adjuster.
- Ensure that the self-made colored links (1, 2) match to the marks on the camshaft position adjuster actuators.
Timing Chain Tensioner(1) - Install
- Timing Chain Tensioner Bolt(2) - Install and tighten 10 N.m (89 lb in)[2x]
Push the timing chain guide - left side (2) in the direction of the arrow.
- Remove the fixing tool (3) from the tensioner (1).
Loosen the EN-51148 holding tool bolts (2, 3, 4).
- Remove the EN-51148 holding tool (1).
Upper Timing Chain Guide(1) - Install
- Upper Timing Chain Guide Bolt(2) - Install and tighten 7 N.m (62 lb in)[2x]
- Check the position of the crankshaft, camshaft and camshaft position actuator adjuster.
- Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer absorber bolt.
Adjust the engine to cylinder 1 top death center (TDC) of combustion stroke. Set crankshaft in direction of engine rotation until the markings (2) and (3) line up. Rotate at the crankshaft balancer absorber bolt (1).
Install the EN-51148 holding tool (1) to camshafts and to the cylinder head.
- Tighten the bolt (3) in the middle.
- Tighten the 2 outer bolts (2, 4).
- If EN-51148 holding tool can be installed, the engine timing is properly adjusted.
- Remove the middle bolt (3) and the 2 outer bolts (2, 4) and remove the EN-51148 holding tool (1).
- Engine Front Cover Replacement - Upper - Install
Install the engine mount (5).
- Install 3 NEW engine mount to engine mount bracket bolts (3) and 3 washers (4).
- Install the 2 engine mount to body bolts (2) and the engine mount nut (1).
- Tighten the 2 engine mount to body bolts (2) and the engine mount nut (1) to 62 N.m (46 lb ft).
- Tighten the 3 NEW engine mount to engine mount bracket bolts (3) a first pass to 50 N.m (37 lb ft).
- Tighten the 3 NEW engine mount to engine mount bracket bolts a final pass to 60 - 75 degrees, using the EN-45059 meter.
Remove the engine lifter (1) from the right engine lift bracket.
- Camshaft Cover Replacement - Install
- Air Cleaner Assembly Replacement - Install
Note the identification marking on the camshaft bearing cover.
The complete installation procedure of the exhaust camshaft rear bearing cap should be done in 10 minutes.
Refer to Torque-to-Yield Fastener Caution .