REMOVAL AND INSTALLATION <4B11-TURBO>


Pre-removal operation
  • Engine Coolant Draining (Refer to ).
  • Engine Upper Cover Removal (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Thermostat Removal (Refer to ).

 Post-installation operation
  • Thermostat Installation (Refer to ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Upper Cover Installation (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Engine Coolant Refilling (Refer to ).




Thermostat case removal steps
<<A>>
 >>D<<
 1.
 Radiator upper hose connection


2.
 Cooling water outlet hose fitting


3.
 Cooling water outlet hose fitting gasket


4.
 Cooling water line hose


5.
 Cooling water line hose


6.
 Engine coolant temperature sensor connector connection


7.
 Heater hose connection


8.
 Earth cable connection


9.
 Control wiring harness connection


10.
 Harness bracket


11.
 Turbocharger water feed hose


12.
 Turbocharger water feed pipe


13.
 Gasket


14.
 Thermostat case


15.
 Thermostat case gasket



Water pump inlet pipe removal steps


14.
 Thermostat case


15.
 Thermostat case gasket


·
 Turbocharger assembly (Refer to GROUP 15 - Exhaust Manifold and Turbocharger Assembly )


16.
 Turbocharger water return hose


17.
 Water pump inlet pipe


18.
 Cooling water line gasket

>>C<<
 19.
 O-ring



Engine coolant temperature sensor removal steps


·
 Fuel injector return pipe (Refer to GROUP 13C - Injector )
<<B>>
 >>B<<
 20.
 Fuel high-pressure hose connection


21.
 Emission control vacuum hose and pipe assembly mounting bolts


6.
 Engine coolant temperature sensor connector connection
<<C>>
 >>A<<
 22.
 Engine coolant temperature sensor

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator upper hose and the hose clamp. Disconnect the radiator upper hose.

<<B>> FUEL HIGH-PRESSURE HOSE DISCONNECTION



1.Follow the steps below to unlock the fuel high-pressure hose connector.
(1) Insert a flat-tipped screwdriver (6 mm wide and 1 mm thick) into the retainer of the fuel high-pressure hose connector.
(2)
caution When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel high-pressure hose connector.
2.Remove the fuel high-pressure hose.

<<C>> ENGINE COOLANT TEMPERATURE SENSOR REMOVAL

Use special tool water temp sensor wrench (MB992042) to remove the engine coolant temperature sensor.

INSTALLATION SERVICE POINTS

>>A<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

1.Apply the specified sealant to the thread of the engine coolant temperature sensor.
Specified sealant: Three bond 1324N or equivalent
note Install the engine coolant temperature sensor within 3 minutes after the application of sealant.

2.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
Use special tool water temp sensor wrench (MB992042) to tighten the engine coolant temperature sensor to the specified torque.
Tightening torque: 30 ± 9 N·m

>>B<< FUEL HIGH-PRESSURE HOSE CONNECTION

1.
caution
  • When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
  • After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm play.
Securely insert the fuel delivery pipe stopper into the fuel high-pressure hose connector groove to install the fuel high-pressure hose to the fuel delivery pipe.
2.Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel delivery pipe.

>>C<< O-RING INSTALLATION
caution Avoid adhesion of engine oil or grease to the O-ring.

Fit the O-ring in the water pump inlet pipe groove, wet the O-ring circumference or the pipe mounting area inner wall, and then insert the O-ring.

>>D<< RADIATOR UPPER HOSE CONNECTION

1.Insert radiator upper hose as far as the projection of the cooling water outlet hose fitting.
2.Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.