REMOVAL AND INSTALLATION <4M4>

<4M40>

Pre-removal and Post-installation Operation

Engine Coolant Draining and Refilling (Refer to ).
Air Cleaner Assembly Removal and Install <4M4> (Refer to GROUP 15 - Air Cleaner ).
Intercooler Air Hose A1 and B Removal and Install (Refer to GROUP 15 - Intercooler ).
Air Intake Pipe Removal and Install (Refer to GROUP 15 - Inlet, Exhaust Manifold and Turbocharger ).

			Removal steps
<<A>>	>>D<<	1.	Radiator upper hose connection
		2.	Engine coolant temperature switch connector
		3.	Water outlet pipe assembly
		4.	Water outlet pipe assembly gasket
	>>C<<	5.	Engine coolant temperature switch
		6.	Engine coolant temperature sensor connector
<<B>>	>>B<<	7.	Engine coolant temperature sensor
<<A>>	>>D<<	8.	Radiator lower hose connection
		9.	By-pass pipe, thermostat case and thermostat cover assembly
	>>A<<	10.	O-ring
	>>A<<	11.	O-ring
	>>A<<	12.	O-ring
		13.	By-pass pipe
		14.	Thermostat case and thermostat cover assembly
	>>A<<	15.	O-ring
		16.	Heater hose connection
		·	Turbocharger assembly, exhaust manifold and inlet manifold (Refer to GROUP 15 - Inlet, Exhaust Manifold and Turbocharger ).
		17.	Heater return pipe assembly

<4M41>

Pre-removal and Post-installation Operation

Engine Cover Removal and Installation (Refer to GROUP 11G - Engine Assembly ).
Engine Coolant Draining and Refilling (Refer to ).
Air Cleaner Assembly Removal and Install <4M4> (Refer to GROUP 15 - Air Cleaner ).
Intercooler Air Hose A1 and B Removal and Install (Refer to GROUP 15 - Intercooler ).

			Removal steps
<<A>>	>>D<<	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 outlet pipe
	>>A<<	9.	O-ring
		10.	Vacuum hose connection
		11.	Vacuum hose connection
		12.	Vacuum pipe assembly
		13.	Turbocharger water outlet pipe
		14.	Gasket
		15.	Turbocharger water inlet pipe
		16.	Gasket
		17.	EGR water inlet hose
		18.	EGR water inlet pipe
	>>A<<	19.	O-ring
		20.	By-pass pipe, thermostat case and thermostat cover assembly
	>>A<<	21.	O-ring
	>>A<<	22.	O-ring
	>>A<<	23.	O-ring
		24.	By-pass pipe
		25.	Thermostat case
	>>A<<	26.	O-ring
		27.	Heater hose connection
		·	Turbocharger assembly and exhaust manifold assembly (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ).
		28.	Heater return pipe

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 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

Apply the sealant to the thread of engine coolant temperature sensor. In the same manner as for removal, using special tool water temp sensor wrench (MB992042), tighten to the specified torque.

Specified sealant: 3M Nut Locking Part No. 4171 or equivalent
Tightening torque: 40 N·m <4M40>
Tightening torque: 30 ± 9 N·m <4M41>

>>C<< ENGINE COOLANT TEMPERATURE SWITCH INSTALLATION

Apply the sealant to the thread of engine coolant temperature switch, and then tighten to the specified torque.

Specified sealant: 3M ATD Part No. 8660 or equivalent
Tightening torque: 34 ± 9 N·m

>>D<< RADIATOR HOSE CONNECTION

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