Rocker Cover and Camshaft
ROCKER COVER AND CAMSHAFTREMOVAL AND INSTALLATION
Removal Steps 1-22:
Removal Steps 23-30:
Required Special Tools:
^ MD998443: Lash Adjuster Holder
^ MD998713: Camshaft Oil Seal Installer
^ MD998777: Camshaft Oil Seal Installer Adapter
^ MB990767: End Yoke Holder
^ MD998719: Pins
REMOVAL SERVICE POINT
[[A]] ROCKER ARMS AND SHAFT, EXHAUST REMOVAL
CAUTION: If the lash adjuster is re-used, clean the lash adjuster.
Set special tool MD998443 to prevent the lash adjuster coming from free and falling to the floor.
[[B]] ROCKER ARM SHAFT ASSEMBLY REMOVAL
CAUTION: Never overhaul the rocker arm shaft assembly.
[[C]] CAMSHAFT POSITION SENSING CYLINDER REMOVAL
Install the camshaft sprocket and the camshaft sprocket bolt to the camshaft. Using the special tools MB990767 and MD998719, prevent the camshaft position sensing cylinder from rotating and remove it.
INSTALLATION SERVICE POINTS
]]A[[ CAMSHAFT, RIGHT / CAMSHAFT, LEFT INSTALLATION
CAUTION: Use care to prevent confusion of the right and left bank camshafts.
1. Apply engine oil to the camshaft journals and cams and then install the camshafts.
NOTE: The left bank camshaft is identified by a slit 4 mm (0.16 inch) wide at the rear end of the camshaft.
2. Install the cylinder head, placing the dowel pin of the camshaft upward.
]]B[[ CAMSHAFT POSITION SENSING CYLINDER INSTALLATION
1. Mate the groove on the camshaft rear end face properly with the protrusion of the camshaft position sensing cylinder so that the camshaft position sensing cylinder can be installed.
2. Install the camshaft sprocket and the camshaft sprocket bolt to the camshaft. Using the special tools MB990767 and MD998719, prevent the camshaft position sensing cylinder from rotating and tighten it to the specified torque.
]]C[[ LASH ADJUSTER INSTALLATION
CAUTION: If the lash adjuster is re-used, clean the lash adjuster.
Fit the lash adjuster onto the rocker arm without allowing diesel fuel to spill out. Fit special tool MD998443 to prevent the lash adjuster coming from free and falling to the floor.
]]D[[ ADJUSTING SCREW INSTALLATION
Install provisionally the screw to rocker arm, insert it so that end of the screw is flush with the edge of the rocker arm or projects slightly 3 mm (0.1 inch).
]]E[[ ROCKER ARMS AND SHAFT / ROCKER SHAFT CAP INSTALLATION
1. In accordance with the tags for the reinstallation, install the rocker arm and so on to the rocker arm shaft.
2. Temporarily install the intake rocker arms and shaft.
NOTE: Place the notch on the end face in the direction shown in the illustration.
3. Temporarily install the exhaust rocker arms shaft.
NOTE: Place the notch on the end face in the direction shown in the illustration.
NOTE: Install the rocker arm shaft with oil hole to the lower (cylinder head) side.
4. Install the rocker shaft cap.
NOTE: Pay attention to the installation direction of the rocker shaft cap at the exhaust side.
5. Confirm the each rocker arm and rocker arm shaft assembly are in position and then tighten to the specified torque.
Tightening torque:
Exhaust side (M6): 13 ± 1 Nm (115 ± 8 in-lb)
Intake side (M8): 31 ± 3 Nm (23 ± 2 ft-lb)
]]F[[ CAMSHAFT OIL SEAL INSTALLATION
1. Use special tools MD998713 and MD998777 to install the camshaft oil seal.
2. Screw the camshaft sprocket bolt until the special tool touches the end face of the cylinder head.
3. Oil seal shall be pressed fit to position.
]]G[[ ROCKER COVER, RIGHT / ROCKER COVER, LEFT INSTALLATION
Tighten the rocker cover to the specified torque in the sequence shown in the illustration.
Tightening torque: 8.3 ± 1.0 Nm (74 ± 8 in-lb)
INSPECTION
CAMSHAFT
Measure the cam height. If it is below the limit, replace the camshaft.
LASH ADJUSTER
CAUTION:
^ The lash adjusters are precision-engineered mechanisms. Do not allow them to become contaminated by dirt or other foreign substances.
^ Do not attempt to disassemble the lash adjusters.
^ Use only fresh diesel fuel to clean the lash adjusters.
1. Prepare three containers and approximately 5 dm3 (30.5 quart) of diesel fuel. Into each container, pour enough diesel fuel to completely cover a lash adjuster when it is standing upright. Then, perform the following steps with each lash adjuster.
2. Place the lash adjuster in container A and clean its outside surface.
NOTE: Use a nylon brush if deposits are hard to remove.
CAUTION: The steel ball spring is extremely weak, so the lash adjuster's functionality may be lost if the air bleed wire is pushed in hard.
3. While gently pushing down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442, move the plunger through five to ten strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will remove dirty oil.
NOTE: If the plunger remains stiff or the mechanism appears otherwise abnormal, replace the lash adjuster
4. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.
CAUTION: The steel ball spring is extremely weak, so the lash adjuster's functionality may be lost if the air bleed wire is pushed in hard.
5. Place the lash adjuster in container B. Then, gently push down the internal steel ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442 and move the plunger through five to ten strokes until it slides smoothly. This operation will clean the lash adjuster's pressure chamber.
6. Remove the lash adjuster from the container. Then, push down the steel ball gently and push the plunger to eliminate diesel fuel from the pressure chamber.
CAUTION: Do not use container C for cleaning. If cleaning is performed in container C, foreign matter could enter the pressure chamber when the chamber is filled with diesel fuel.
7. Place the lash adjuster in container C. Then, gently push down the internal steel ball using a wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442.
8. Stand the lash adjuster with its plunger at the top, then push the plunger downward firmly until it moves through its greatest possible stroke. Return the plunger slowly, then release the steel ball and allow the pressure chamber to fill with diesel fuel.
9. Remove the lash adjuster from the container, then stand the lash adjuster with its plunger at the top. Push the plunger firmly and check that it does not move.
NOTE: If the lash adjuster contracts or moves, repeat steps 7 through 9 again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts or moves after performing these steps.
10. Stand the lash adjuster upright to prevent diesel fuel from spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Install the lash adjuster onto the engine as soon as possible.