REMOVAL AND INSTALLATION

Pre-removal Operation

Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
Front Deck Garnish Removal (Refer to GROUP 51 - Windshield Wiper ).
Throttle Body Removal (Refer to ).
EGR Valve and EGR Pipe Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
Inlet Manifold Removal (Refer to GROUP 15 - Inlet Manifold ).
Fuel Injection Pipe Removal (Refer to ).

Post-installation Operation

Fuel Injection Pipe Installation (Refer to ).
Inlet Manifold Installation (Refer to GROUP 15 - Inlet Manifold ).
EGR Valve and EGR Pipe Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ).
Throttle Body Installation (Refer to ).
Front Deck Garnish Installation (Refer to GROUP 51 - Windshield Wiper ).
Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
Air Bleeding from Fuel Line (Refer to ).

			Removal steps
		·	When the fuel injector is replaced, register the injector identification code and perform the fuel injection learning (Refer to GROUP 00 - Precautions before Service, What the Common Rail Engine Learns ) <Installation only>.
		1.	Breather hose connection
		2.	Timing belt front upper cover
	>>D<<	3.	Oil seal
	>>D<<	4.	Oil seal
<<A>>	>>C<<	5.	Rocker cover assembly
		6.	Rocker cover gasket A
		7.	Rocker cover gasket B
		8.	Rocker cover gasket C
	>>B<<	9.	Semi-circular packing
	>>A<<	10	Eye bolt
	>>A<<	11.	Fuel leakage pipe
	>>A<<	12.	Fuel leak-off gasket
	>>A<<	13.	Injector holder bolt
	>>A<<	14.	Injector supporter
	>>A<<	15.	Pivot boss
	>>A<<	16.	Fuel injector
	>>A<<	17.	Nozzle gasket

REMOVAL SERVICE POINT

<<A>> ROCKER COVER ASSEMBLY REMOVAL

1.Turn the crankshaft clockwise, and remove the timing belt rear cover mounting bolts shown in the figure from the gap of the camshaft sprocket.

2.In the order shown in the figure, loosen the rocker cover assembly mounting bolts, and then remove the rocker cover assembly.

INSTALLATION SERVICE POINTS

>>A<< NOZZLE GASKET/FUEL INJECTOR/PIVOT BOSS/INJECTOR SUPPORTER/INJECTOR HOLDER BOLT/FUEL LEAK-OFF GASKET/FUEL LEAKAGE PIPE/EYE BOLT INSTALLATION

1.Install the nozzle gasket, fuel injector, pivot boss, and injector supporter to the cylinder head as shown in the figure.
2.Apply a small amount of engine oil to the seat surface and thread of injector holder bolt, and then temporarily tighten the bolt to the cylinder head.
3.Set the fuel leak-off gasket to the fuel leakage pipe, and temporarily tighten to the fuel injector and to the cylinder head using the eye bolt.
4.Tighten the eye bolt of the fuel injector side to the specified torque.
Tightening torque: 15 ± 2 N·m
5.Tighten the eye bolt of the cylinder head side to the specified torque.
Tightening torque: 15 ± 2 N·m
6.Tighten the injector holder bolt to the specified torque.
Tightening torque: 10 ± 1 N·m

caution

If the bolt is tightened less than the specified lower limit of 120 degree angle, the bolt may become loose. Be sure to tighten correctly.
If the bolt is tightened in excess of the specified upper limit of 125 degree angle, loosen the nut completely and repeat the entire procedures.

Using special tool angle gauge (MB991614), tighten the injector holder bolt in the illustrated sequence by a further 120 to 125 degree angle.

>>B<< SEMI-CIRCULAR PACKING INSTALLATION

Apply specified sealant to portions indicated in illustration.
Specified sealant: 3M ATD Part No. 8660 or equivalent

>>C<< ROCKER COVER ASSEMBLY INSTALLATION

1.Apply specified sealant to portions indicated in illustration.
Specified sealant: 3M ATD Part No. 8660 or equivalent
2.Install the rocker cover assembly to the cylinder head.

3.Tighten the cylinder head assembly mounting bolt to the specified torque in the order shown in the figure.
Tightening torque: 3.0 ± 1.0 N·m
4.Again, tighten the cylinder head assembly mounting bolt to the specified torque in the order shown in the figure.
Tightening torque: 10 ± 2 N·m

>>D<< OIL SEAL INSTALLATION

Apply engine oil to the oil seal outer surface and drive in with a socket wrench.