REMOVAL AND INSTALLATION <4M4 (Emission regulation Euro 5)>


caution Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
Pre-removal and Post-installation Operation
  • Engine Cover Removal and Installation (Refer to GROUP 11C - Engine Assembly ).
  • Engine Coolant Draining and Refilling (Refer to ).




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


2.
 Water hose


3.
 Engine coolant temperature sensor connector
<<B>>
 >>B<<
 4.
 Engine coolant temperature sensor


5.
 Cooling water outlet pipe


6.
 Gasket


7.
 EGR water outlet hose


8.
 EGR water hose B


9.
 EGR water outlet pipe

>>A<<
 10.
 O-ring


11.
 Vacuum hose connection


12.
 Vacuum hose connection


13.
 Vacuum hose connection


14.
 Vacuum hose connection


15.
 Vacuum pipe assembly


16.
 Turbocharger water pipe A


17.
 Water hose assembly


18.
 Water hose assembly


19.
 Turbocharger water pipe B


20.
 Gasket


21.
 EGR water inlet hose


22.
 EGR water hose A


23.
 EGR water inlet pipe

>>A<<
 24.
 O-ring


25.
 Heater hose connection


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


26.
 Heater return pipe


27.
 O-ring


28.
 By-pass pipe

>>A<<
 29.
 O-ring


30.
 Thermostat case


31.
 Gasket

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE DISCONNECTION

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

<<B>> ENGINE COOLANT TEMPERATURE SENSOR REMOVAL

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

INSTALLATION SERVICE POINTS

>>A<< O-RING INSTALLATION
caution Care must be taken not to permit engine oil or other greases to adhere to the O-ring.
Insert the O-ring to pipe, and coat the outer circumference of the O-ring with water.

>>B<< ENGINE COOLANT TEMPERATURE SENSOR INSTALLATION

1.Apply the sealant to the thread of engine coolant temperature sensor.
Specified sealant: ThreeBond 1324N or equivalent
note Install the engine coolant temperature sensor immediately after applying 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.
In the same manner as for removal, using special tool water temperature sensor wrench (MB992042), tighten to the specified torque.
Tightening torque: 30 ± 9 N·m

>>C<< RADIATOR UPPER HOSE CONNECTION

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