REMOVAL AND INSTALLATION

<4G63>

Pre-removal Operation

Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) .]

Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).

Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).

Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ).

Exhaust Manifold Removal (Refer to GROUP 15, Exhaust Manifold ).

Spark Plug Cables and Ignition Coils Removal (Refer to GROUP 16, Ignition Coil ).

Post-installation Operation

Spark Plug Cables and Ignition Coils Installation (Refer to GROUP 16, Ignition Coil ).

Exhaust Manifold Installation (Refer to GROUP 15, Exhaust Manifold ).

Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ).

Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).

Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).

Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service - Accelerator Cable Check and Adjustment ).

Fuel Leak Check

		Removal steps
	1.	Accelerator cable connection
	2.	A/C compressor connector
	3.	Power steering oil pressure switch connector
<<A>>	4.	Crank angle sensor connector
	5.	Ignition coil connectors
	6.	Throttle position sensor connector
	7.	Manifold absolute pressure sensor connector
	8.	EGR control solenoid valve connector
	9.	Purge control solenoid valve connector
	10.	Detonation sensor connector
	11.	Injector connectors
	12.	Engine coolant temperature gauge unit connector
	13.	Idle speed control servo connector
	14.	Oxygen sensor connector
	15.	Camshaft position sensor connector
	16.	Engine coolant temperature sensor connector
	17.	Capacitor connector
	18.	Earth cable connection
	19.	Brake booster vacuum hose connection
	20.	Engine oil level gauge and guide assembly
	21.	O-ring

			Removal steps
		22.	Rocker cover PCV hose connection
		23.	Rocker cover breather hose connection
		24.	Vacuum hose connection
		25.	Battery wiring harness connection
		26.	Inlet manifold stay
		•	Timing belt upper cover (Refer to ).
<<B>>	>>E<<	27.	Camshaft sprocket
<<C>>	>>D<<	28.	Radiator upper hose connection
		29.	Water hose connection
		•	Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
		30.	Fuel return line hose connection
	>>C<<	31.	Fuel high-pressure hose connection
	>>C<<	32.	O-ring
		33.	Rocker cover
		34.	Rocker cover gasket
<<D>>	>>B<<	35.	Cylinder head bolts
		36.	Cylinder head assembly
	>>A<<	37.	Cylinder head gasket

<4G64>

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 Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).

Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).

Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ).

Exhaust Manifold Removal (Refer to GROUP 15, Exhaust Manifold ).

Spark Plug Cables and Ignition Coils Removal (Refer to GROUP 16, Ignition Coil ).

Post-installation Operation

Spark Plug Cables and Ignition Coils Installation (Refer to GROUP 16, Ignition Coil ).

Exhaust Manifold Installation (Refer to GROUP 15, Exhaust Manifold ).

Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ).

Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).

Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).

Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service - Accelerator Cable Check and Adjustment ).

Fuel Leak Check

		Removal steps
	1.	Accelerator cable connection
	2.	A/C compressor connector
	3.	Power steering oil pressure switch connector
<<A>>	4.	Crank angle sensor connector
	5.	Ignition coil connectors
	6.	EGR control solenoid valve connector
	7.	Detonation sensor connector
	8.	Throttle position sensor connector
	9.	Injector connectors
	10.	Engine coolant temperature gauge unit connector
	11.	Idle speed control servo connector
	12.	Camshaft position sensor connector
	13.	Engine coolant temperature sensor connector
	14.	Capacitor connector
	15.	Earth cable connection
	16.	Brake booster vacuum hose connection
	17.	Auto-cruise control vacuum hose connection <Vehicles with auto-cruise control>
	18.	Canister vacuum hose connection
	19.	Engine oil level gauge and guide assembly
	20.	O-ring

			Removal steps
		21.	Rocker cover PCV hose connection
		22.	Rocker cover breather hose connection
		23.	Detonation sensor connector
		24.	Battery wiring harness connection
		25.	Inlet manifold stay
		•	Timing belt upper cover (Refer to ).
<<B>>	>>E<<	26.	Camshaft sprocket
<<C>>	>>D<<	27.	Radiator upper hose connection
		28.	Water hose connection
		•	Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
		29.	Fuel return line hose connection
	>>C<<	30.	Fuel high-pressure hose connection
	>>C<<	31.	O-ring
		32.	Rocker cover
		33.	Rocker cover gasket
<<D>>	>>B<<	34.	Cylinder head bolts
		35.	Cylinder head assembly
	>>A<<	36.	Cylinder head gasket

REMOVAL SERVICE POINTS

<<A>> CRANK ANGLE SENSOR CONNECTOR REMOVAL

CAUTION

Do not remove the tape securing the crank angle sensor connector and control wiring harness, since the control wiring harness may contact the power steering oil pump pulley.

<<B>> CAMSHAFT SPROCKET REMOVAL

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.

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

CAUTION

The special tool can be gradually installed at a rate of a 30 degree turn per second. If it is screwed in all at once, the timing belt tensioner adjuster rod will not easily retract and the special tool may bend.

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

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

CAUTION

Do not rotate the crankshaft after camshaft sprocket removal.

Use the special tool below to remove the camshaft sprocket and the valve timing belt as an assembly.
- Front hub and flange yoke holder (MB990767)
- Pin (MD998719)
Place the camshaft sprocket above the timing belt lower cover.

<<C>> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

<<D>> CYLINDER HEAD BOLTS REMOVAL

Using special tool cylinder head bolt wrench (MB991654), loosen the cylinder head bolts in two or three steps in the order of the numbers shown in the illustration.

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION

Do not allow any foreign materials to get into the coolant passages, oil passages and cylinder.

Remove the gasket from the cylinder head and cylinder block.

Assemble to the cylinder block so the cylinder head gasket identification mark "63" or "64" is at the top surface and on the exhaust side.

>>B<< CYLINDER HEAD BOLTS INSTALLATION

Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one.

Limit (A): 99.4 mm

Apply a small amount of engine oil to the thread of the bolts and to the washers.

Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts as follows:

Tighten the cylinder head bolts to 78 ± 2 N·m in the order shown.

Loosen the bolts fully in the reverse order of that shown.

Tighten the cylinder head bolts to 20 ± 2 N·m in the order shown.

Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown.

CAUTION

The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle.

Tighten the bolt an additional 90 degree angle as shown. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned.

If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.

>>C<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

Do not let any engine oil get into the delivery pipe.

Apply a small amount of new engine oil to the O-ring.

Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly.

If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly.

Tighten the fuel high-pressure hose mounting bolts to the specified torque.

Tightening torque: 5.0 ± 1.0 N·m

>>D<< RADIATOR UPPER HOSE CONNECTION

Insert each hose as far as the projection of the water outlet fitting.

Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

>>E<< CAMSHAFT SPROCKET INSTALLATION

Use the following special tool as during removal to support the camshaft sprocket.

Front hub and flange yoke holder (MB990767)

Pin (MD998719)

Tighten the camshaft sprocket mounting bolts to the specified torque.

Tightening torque: 89 ± 9 N·m

Remove special tool adjusting bolt (MD998738), then assemble the timing belt under cover rubber plug.