REMOVAL AND INSTALLATION <6B3>


Pre-removal operation
  • Engine Coolant Draining <4B1, 6B3> (Refer to ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner <6B3> ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Thermostat Removal <6B3> (Refer to ).

 Post-installation operation
  • Thermostat Installation <6B3> (Refer to ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner <6B3> ).
  • Engine Coolant Refilling <4B1, 6B3> (Refer to ).




Removal steps
<<A>>
 >>D<<
 1.
 Radiator upper hose connection


2.
 EGR valve connector


3.
 EGR water hose


4.
 EGR water hose


5.
 EGR valve


6.
 EGR valve gasket


7.
 EGR pipe


8.
 EGR pipe gasket


9.
 EGR pipe gasket


10.
 Engine coolant temperature sensor connector
<<B>>
 >>C<<
 11.
 Engine coolant temperature sensor


12.
 Earth cable connection


13.
 Water hose


14.
 Water hose


15.
 Heater hose connection


16.
 A/T fluid cooler water return hose and pipe assembly connection


17.
 Harness bracket


·
 Oil pipe clamp bolt (Refer to GROUP 11C - Cylinder Head Gasket ).


18.
 Water hose
<<C>>
 >>B<<
 19.
 Thermostat housing

>>B<<
 20.
 Thermostat housing gasket

>>B<<
 21.
 Thermostat housing gasket


22.
 Water inlet pipe

>>A<<
 23.
 O-ring

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>> ENGINE COOLANT TEMPERATURE SENSOR REMOVAL

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

<<C>> THERMOSTAT HOUSING REMOVAL

Remove the two control wiring harness clamps, and remove the thermostat housing.

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION
caution Do not allow engine oil or other grease to adhere to the O-ring

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

>>B<< THERMOSTAT HOUSING GASKET/THERMOSTAT HOUSING INSTALLATION

Using the special tool guide (MD998412), install the thermostat housing while supporting the thermostat housing gasket.

>>C<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

1.Apply the specified sealant to the thread of the engine coolant temperature sensor.
Specified Sealant: Three bond 1324N, Loctite 262 or equivalent

2.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

>>D<< RADIATOR UPPER HOSE INSTALLATION

1.Insert radiator upper hose as far as the projection of the thermostat housing.
2.Align the mating marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.