Rocker Arms and Camshaft

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINT
[[A]] ROCKER ARM AND ROCKER ARM SHAFT REMOVAL

CAUTION: If the lash adjuster is re-used, clean the lash adjuster.





Set special tool MD998443 to prevent the lash adjuster coming free and falling to the floor.

INSTALLATION SERVICE POINTS
]]A[[ 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 free and falling to the floor.

]]B[[ ROCKER ARM SHAFT INSTALLATION





Install the rocker arm shafts, place the end with notched side toward the timing belt side as shown.

]]C[[ ROCKER ARMS AND ROCKER ARM SHAFT INSTALLATION





Move the rocker arms in the directions shown in the illustration before tightening the rocker arm shaft bolts.

]]D[[ ROCKER ARM SPRING INSTALLATION





1. Insert the rocker arm spring at an angle to the spark plug guide and then install it so that it is at a right angle to the guide.
2. Remove the special tool from rocker arms.

]]E[[ OIL SEAL INSTALLATION





Use special tool MD998713 to install the camshaft oil seal.

INSPECTION
CAMSHAFT





Measure the cam height and replace the camshaft if any height exceeds the specified limit.
Standard value:
Intake: 37.86 mm (1.49 inches)
Exhaust: 37.67 mm (1.48 inches)
Limit:
Intake: 37.36 mm (1.47 inches)
Exhaust: 37.17 mm (1.46 inches)

LASH ADJUSTERS

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.





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 5 to 10 strokes until it slides smoothly. In addition to eliminating stiffness in the plunger, this operation will removed dirty oil.

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.

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.





5. Place the lash adjuster in container B. Then, gently push down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442 and move the plunger through 5 to 10 strokes until it slides smoothly. This operation will clean the lash adjuster's 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.





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.





7. Place the lash adjuster in container C. Then, gently push down the internal steel ball using wire [0.5 mm (0.020 inch) in diameter] or special tool MD998442.

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.





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. Also, check that the lash adjuster's height matches that of a new lash adjuster.

NOTE: If lash adjuster contracts, perform the operations (7) through (9) again to fill it with diesel fuel completely. Replace the lash adjuster if it still contracts after performing these steps.

10. Stand the lash adjuster upright to prevent diesel fuel spilling out. Do not allow the lash adjuster to become contaminated by dirt or other foreign matter. Fit the lash adjuster onto the engine as soon as possible.