REMOVAL AND INSTALLATION



Pre-removal Operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13A - On-vehicle Service, How to Reduce Pressurized Fuel Lines ).
  • Engine Room Under Cover Front A, B, D and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Air Cleaner Intake Hose and Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Ignition Coil Removal (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold ).
  • Throttle Body Assembly Removal (Refer to GROUP 13A - Throttle Body Assembly ).
  • Thermostat Case Removal (Refer to GROUP 14A - Water Hose and Water Pipe ).

Post-installation Operation
  • Thermostat Case Installation (Refer to GROUP 14A - Water Hose and Water Pipe ).
  • Throttle Body Assembly Installation (Refer to GROUP 13A - Throttle Body Assembly ).
  • Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold ).
  • Ignition Coil Installation (Refer to GROUP 16 - Ignition System, Ignition Coil ).
  • Air Cleaner Intake Hose and Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Coolant Refilling (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Room Under Cover Front A, B, D and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).
  • Fuel Leak Check.





Removal steps


1.
Control wiring harness connection
<<A>>
>>G<<
2.
Hose clip
<<A>>
>>G<<
3.
Radiator upper hose connection
<<A>>
>>G<<
4.
Hose clip
<<A>>
>>G<<
5.
Radiator lower hose connection


6.
Heater hose connection


7.
Water pump line pipe


8.
Cooling water line gasket


9.
O-ring


10.
Canister vacuum hose connection


11.
Brake booster vacuum hose connection


12.
Engine oil level gauge


13.
Inlet manifold stay


14.
Rocker cover PCV hose connection
<<B>>
>>F<<
15.
Fuel high-pressure hose connection





Removal steps


·
Valve timing chain (Refer to )
<<C>>
>>E<<
16.
Camshaft bearing front cap assembly

>>C<<
17.
Camshaft bearing
<<D>>
>>D<<
18.
Camshaft bearing oil feeding cap
<<D>>
>>D<<
19.
Camshaft bearing cap
<<D>>
>>D<<
20.
Camshaft bearing cap
<<D>>
>>D<<
21.
Camshaft bearing thrust cap

>>C<<
22.
Camshaft and camshaft sprocket assembly

>>C<<
23.
Camshaft bearing
<<E>>
>>B<<
24.
Cylinder head bolt
<<E>>
>>B<<
25.
Cylinder head bolt assembly

>>A<<
26.
Cylinder head assembly

>>A<<
27.
Cylinder head gasket

REMOVAL SERVICE POINTS



<<A>> HOSE CLIP/RADIATOR HOSE DISCONNECTION



1.Make mating marks on the radiator hose and the hose clip as shown to install them in the original position.

2.Break off the tip of hose clip claw and spread out the hose clip, then disconnect the radiator lower hose.
note If there is a hose clip claw, the hose clip cannot spread to capacity because the claw contacts the hose clip.

<<B>> FUEL HIGH-PRESSURE HOSE REMOVAL



1.Remove the stopper of the fuel high-pressure hose.

2.Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.
note If the retainer is released, install it securely after removing the fuel high-pressure hose.

<<C>> CAMSHAFT BEARING FRONT CAP ASSEMBLY REMOVAL


1.Temporarily install the engine oil pan which was removed at the valve timing chain removal (Refer to ).
2.
caution When supporting the engine and transmission assembly with a garage jack, be careful not to deform the engine oil pan.
Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transmission assembly.


3.Remove special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed.
caution Be careful not to drop the camshaft bearing.

Loosen the camshaft bearing front cap mounting bolts in the order of number shown in the figure, and remove the camshaft bearing front cap assembly.

<<D>> CAMSHAFT BEARING OIL FEEDING CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING THRUST CAP REMOVAL


caution When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are damaged. Always loosen the mounting bolts in four or five steps.

Loosen the camshaft bearing caps mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.

<<E>> CYLINDER HEAD BOLT/CYLINDER HEAD BOLT ASSEMBLY REMOVAL



Loosen and remove the bolts in two or three steps in the order of number shown in the figure.

INSTALLATION SERVICE POINTS



>>A<< CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION



1.
caution Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
Wipe off the sealant and grease on the top surface of the cylinder block and the bottom surface of the cylinder head, and degrease the surface where the sealant is applied.

2.Apply the sealant to the top surface of the cylinder block as shown.
Specified sealant: Three bond 1217G or equivalent
3.Install the cylinder head gasket to the cylinder block.
note
  • Install the cylinder head gasket immediately after the application of sealant.
  • When the cylinder head gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.
4.Apply the sealant to the top surface of the cylinder head gasket as shown.
Specified sealant: Three bond 1217G or equivalent
5.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Install the cylinder head assembly.

>>B<< CYLINDER HEAD BOLT ASSEMBLY/CYLINDER HEAD BOLT INSTALLATION


1.Replace a cylinder head bolts with a new one.
2.For two bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the bolts.
3.Apply a small amount of engine oil to the cylinder head bolt threads and the washers.


4.Tighten the cylinder head bolts by the following procedure (plastic region angular tightening method).
(1) Tighten the cylinder head bolts to the specified torque in the order shown in the figure in two or three steps.
Tightening torque: 35 ± 2 N·m
(2)
caution
  • The cylinder head bolt is not tightened sufficiently if the tightening angle is less than a 180 degrees angle.
  • If the tightening angle exceeds the standard specification, remove the cylinder head bolt and repeat the installation steps from Step 1.
Put a paint mark on the cylinder head bolt head and cylinder head, tighten to 180 ± 2 degrees in the order shown in the figure, and check that the paint mark on the cylinder head bolt head aligns with the paint mark on the cylinder head.

>>C<< CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY INSTALLATION


caution
  • Be careful not to drop the camshaft bearing.
  • When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.


When replacing the camshaft bearing, select a camshaft bearing in relevant size according to the camshaft bearing front cap identification mark in the table below. Identification mark of the camshaft bearing is painted in the position shown in the figure.
Camshaft
Camshaft bearing identification mark
Identification mark
Journal diameter mm
1
40.000 - 40.008
1
2
40.008 - 40.016
2
3
40.016 - 40.024
3

>>D<< CAMSHAFT BEARING THRUST CAP/CAMSHAFT BEARING CAP/CAMSHAFT BEARING OIL FEEDING CAP INSTALLATION



1.Install the camshaft bearing caps to the cylinder head.
note Because the camshaft bearing thrust cap and camshaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the inlet and exhaust sides for correct installation.
2.Tighten each camshaft bearing cap mounting bolts to the specified torque in the order of number shown in the figure in two or three steps.
Tightening torque: 12 ± 1 N·m

>>E<< CAMSHAFT BEARING FRONT CAP ASSEMBLY INSTALLATION



1.
caution When the mounting bolts are tightened with the camshaft bearing front cap tilted, the camshaft bearing front cap is damaged. Install the camshaft bearing front cap properly to the cylinder head and camshaft.
Install the camshaft bearing front cap to the cylinder head, and temporarily tighten the camshaft bearing front cap mounting bolts to the specified torque in the order shown in the figure (1).
Tightening torque: 17 ± 3 N·m
2.Tighten the camshaft bearing front cap mounting bolts to the specified torque again in the order shown in the figure (2).
Tightening torque: 30 ± 2 N·m


3.Install special tool engine hanger (MB991928 or MB991895) which was installed for supporting the engine and transmission assembly when the valve timing chain was removed (Refer to ).
4.Remove the garage jack which supports the engine and transmission assembly.
5.Remove the engine oil pan installed temporarily.

>>F<< FUEL HIGH-PRESSURE HOSE INSTALLATION


caution After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 3-mm play. After the check, install the stopper securely.


Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.

>>G<< RADIATOR HOSE/HOSE CLIP CONNECTION


1.
caution Never reuse the hose clip whose claw is broken off to prevent the rusting.
Make mating mark on a new hose clip in the same position as the remove one.

2.Insert the radiator hose until the protrusion of the pipe.
3.Align the mating marks on the radiator hose and hose clip.
4.Remove the hose clip claw and shorten the hose clip, then install the radiator hose.