REMOVAL AND INSTALLATION


Pre-removal operation
  • Fuel Line Pressure Reduction [Refer to GROUP 13B - On-vehicle Service, Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Alternator Removal (Refer to GROUP 16 - Charging System, Alternator Assembly ).
  • Thermostat Housing Removal (Refer to GROUP 14 - Water Hose and Water Pipe ).
  • Intake Manifold Removal (Refer to GROUP 15 - Intake Manifold ).
  • Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold ).
  • Timing Belt Removal (Refer to ).

 Post-installation operation
  • Timing Belt Installation (Refer to ).
  • Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold ).
  • Intake Manifold Installation (Refer to GROUP 15 - Intake Manifold ).
  • Thermostat Housing Installation (Refer to GROUP 14 - Water Hose and Water Pipe ).
  • Alternator Installation (Refer to GROUP 16 - Charging System, Alternator Assembly ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Fuel Leak Check




Removal steps


1.
 PCV hose connection


2.
 Engine oil level gauge


3.
 O-ring


4.
 Ignition coil connector


5.
 Ignition coil


6.
 Rocker cover


7.
 Rocker cover gasket


8.
 Oil pipe


9.
 Gasket


10.
 Camshaft position sensor connector
<<A>>
 >>B<<
 11.
 Camshaft sprocket


12.
 Idler pulley


13.
 Timing belt rear cover
<<B>>
 >>A<<
 14.
 Left bank cylinder head assembly

>>A<<
 15.
 Cylinder head gasket


16.
 Breather hose connection


17.
 Ignition coil connector


18.
 Ignition coil


19.
 Rocker cover


20.
 Rocker cover gasket


21.
 Oil feeder control valve connector
<<B>>
 >>A<<
 22.
 Right bank cylinder head assembly

>>A<<
 23.
 Cylinder head gasket

REMOVAL SERVICE POINTS

<<A>> CAMSHAFT SPROCKET REMOVAL

Use the following special tools to remove the camshaft sprocket.

  • Front hub and flange yoke holder (MB990767)
  • Pin (MD998719)

<<B>> CYLINDER HEAD ASSEMBLY REMOVAL

Loosen the bolts in two or three steps in the order of the numbers shown in the illustration, and remove them.

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION
1.
caution Be careful that no foreign material gets into the cylinder, coolant passages or oil passages. Engine damage may result.
Use a scraper to clean the gasket surface of the cylinder head assembly and cylinder block.
2.Install the cylinder head gasket and cylinder head assembly to the cylinder block.

3.Check in the following procedure before reusing the cylinder head bolt.
(1) Measure the outside diameter "A".
(2) Measure the smallest outside diameter "B" within the range "X" shown in the illustration.
(3) If the difference of outside diameter of thread exceeds the limit, replace the cylinder head bolt.
Limit: 0.1mm


4.Tighten the bolts to the specified torque in the order shown in the illustration (in two or three cycles).
Tightening torque: 45 ± 2 N·m

5.
caution
  • When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
  • When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
Using special tool angle gauge (MB991614), tighten the cylinder head bolt another 150 to 154 degrees again.

>>B<< CAMSHAFT SPROCKET INSTALLATION

1.Use the following special tools in the same way as during removal to install 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: 90 ± 10 N·m