Special Tools

1. Lightly coat the sliding surfaces with oil.
2. Using the KM-845 , insert the 16 cup tappets.

Important: Note the identification marking on the camshaft bearing cover.

3. Tighten the camshaft bearing caps 2-5 in a spiral from the inside to the outside.

Tighten
Tighten the camshaft bearing caps to 8 N·m (71 lb in).

4. Install the intake camshaft.

Specification
Coat the intake camshaft with MoS 2 lubricating paste.

5. Install the camshaft bearing cover.




Important: Note the identification marking on the camshaft bearing cover.

6. Tighten the camshaft bearing caps 2-5 in a spiral from the inside to the outside.

Tighten
Tighten the camshaft bearing caps 8 N·m (71 lb in).

7. Install the exhaust camshaft.

Specification
Coat the exhaust camshaft with MoS 2 lubricating paste.

8. Install the camshaft bearing cover.




Important: Sealing surfaces must be free from oil and grease.

9. Using a suitable tool, such as a plastic wedge, clean the 1st camshaft bearing support sealing surfaces and the cylinder head sealing surfaces.

Clean the oil duct, arrow, from any sealant residue.





Important: 

•	It is essential to ensure that no sealant is applied outside the marked sealing areas.

•	The grooves (1) adjacent to the sealing surfaces must remain free from sealant.

10. Apply green surface sealant, thinly and evenly, to the 1st camshaft bearing support sealing surfaces, arrows.

Notice: Refer to Fastener Notice in the Preface section.

11. Position the camshaft bearing bridge on the cylinder block and tighten the bolts hand-tight, approximately 2 N·m (18 lb in).



12. Install the 2 camshaft seal rings.

12.1.

Using the KM-422  (4), tighten the seal ring on the camshaft until this is in contact with the cylinder head.

12.2.

To install, use camshaft sprocket bolt (1) in conjunction with shims (2) with a total thickness of approximately 10 mm (0.39 in).

12.3.

Remove the KM-422 .

12.4.

Remove the bolt.





Important: 

•	Ensure no sealant reaches the camshafts.

•	Note the installation sequence 1-4.

13. Install the 1st camshaft bearing support and the 4 bolts.

Tighten
Tighten the 4 bolts to 8 N·m (71 lb in).

14. Insert the MK-6628 .
15. Turn the intake camshaft against the direction of engine rotation
16. Insert the MK-6628 .
17. Turn the exhaust camshaft in the direction of rotation of the engine.
18. Insert the MK-6628 .




Important: Screw in the bolt, but do not tighten.

19. Attach the intake camshaft adjuster or exhaust camshaft adjuster.
20. Insert the MK-6340 in the camshaft adjuster.

Important: 

•	The spot-type marking (4) on the intake camshaft adjuster does not correspond to the groove of the MK-6340 -Left during this process, but must be somewhat above, as shown.

•	The spot-type marking (3) on the exhaust camshaft adjuster must correspond to the groove on the MK-6340 -Right.

21. Insert the MK-6340 -Left (1) and the MK-6340 -Right (2) in the camshaft adjuster, as shown.

Important: A second person is required.

22. Counterhold at camshaft hexagon.
23. Install the intake camshaft adjuster or exhaust camshaft adjuster and bolt.

Tighten
Tighten the bolt to 65 N·m + 120 degrees + 15 degrees (48 lb ft + 120 degrees + 15 degrees.

24. Replace the seal ring and tighten the closure bolt.

Tighten
Tighten the bolt to 30 N·m (22 lb ft).