REMOVAL AND INSTALLATION

Removal steps 1. Control wiring harness connection 2. Battery wiring harness connection 3. Breather hose, transmission fluid level gauge & guide assembly 4. O-ring 5. Radiator lower hose clamp 6. Transmission fluid level gauge bracket 7. Canister vacuum hose connection >>F<< 8. Brake booster vacuum hose connection 9. Engine oil level gauge and guide assembly 10. O-ring

Removal steps 11. Detonation sensor connection 12. Battery wiring harness connection 13. Inlet manifold stay · Exhaust manifold (Refer to GROUP 15, Exhaust Manifold ). · Timing belt upper cover (Refer to ). <<A>> >>E<< 14. Camshaft sprocket <<B>> >>D<< 15. Radiator upper hose connection <<B>> >>D<< 16. Hose clip 17. Water hose connection <Vehicles for Hong kong> 18. Water hose connection · Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ). 19. Fuel return hose connection <<C>> >>C<< 20. Fuel high-pressure hose connection · Rocker cover assembly (Refer to ). <<D>> >>B<< 21. Cylinder head bolts 22. Cylinder head assembly >>A<< 23. Cylinder head gasket

1. caution Never turn the crankshaft anti-clockwise. Turn the crankshaft clockwise, align the timing marks on the camshaft sprocket to set No.1 cylinder to TDC of its compression stroke.

2.Remove the timing belt under cover rubber plug and then set special tool adjusting bolt (MD998738).

3.Screw in the special tool until it comes in contact with the timing belt tensioner arm.

4.Secure the camshaft sprocket and valve timing belt with wiring bands and so on to prevent slippage between the camshaft sprocket and valve timing belt.

5.Use the following special tools to hold the camshaft sprocket. Front hub and flange yoke holder (MB990767) Pin (MD998719) 6. caution Do not rotate the crankshaft after camshaft sprocket removal. Remove the camshaft sprocket with the valve timing belt and place it on the timing belt lower cover.

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

1.Remove the fuel high-pressure hose stopper.

2.Remove the fuel high-pressure hose in the direction shown in the figure while the retainer is pulled up. note If the retainer is released, install it after removing the fuel high-pressure hose.

Use special tool cylinder head bolt wrench (MB991654) to loosen the cylinder head bolts in two or three steps in the order of the numbers shown in the illustration. If the cylinder head bolts cannot be pulled out due to the washer being trapped in the valve spring, raise the bolt slightly, then remove it while holding it by using a magnet.

2.Assemble to the cylinder block so the cylinder head gasket identification mark of "381" is at the top surface and on the exhaust side.

1.Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolts with a new one. Limit (A): 99.4 mm 2.Apply a small amount of engine oil to the thread of the bolts and to the washers.

3.Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts in the following procedures. (1) Tighten the bolts to 78 ± 2 N·m in the order shown. (2) Loosen the bolts fully in the reverse sequence to that shown. (3) Tighten the bolts to 20 ± 2 N·m in the order shown. (4) Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown. (5) caution The bolt is not tightening sufficiently if the tightening angle is less than a 90 degree angle. If the tightening angle exceeds the standard specification, remove the bolt and start over from step 1. Tighten in a 90 degree angle as shown in the instructions of the figure, then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head is on a linear line.

caution After connecting the fuel high-pressure hose, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm. Then install the stopper securely. Apply a small amount of engine oil to the fuel line pipe and then install the fuel high-pressure hose.

1.Use the following special tool as during removal to hold the camshaft sprocket. Front hub and flange yoke holder (MB990767) Pin (MD998719) 2.Tighten the camshaft sprocket mounting bolt to the specified torque. Tightening torque: 89 ± 9 N·m

1.Insert the brake booster vacuum hose thoroughly until it contacts the inlet manifold so that its mating mark faces towards the direction shown. 2.Secure the brake booster vacuum hose with hose clip.