REMOVAL AND INSTALLATION

Pre-removal Operation

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

Under Cover Removal (Refer to GROUP 51, Under Cover ).

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 ).

Intercooler Removal (Refer to GROUP 15, Intercooler ).

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

Battery Removal

Rocker Cover Centre Cover Removal (Refer to ).

Valve Timing Belt Removal (Refer to ).

Post-installation Operation

Valve Timing Belt Installation (Refer to ).

Rocker Cover Centre Cover Installation (Refer to ).

Battery Installation

Air Cleaner Installation (Refer to GROUP 15, Air Cleaner ).

Intercooler Installation (Refer to GROUP 15, Intercooler ).

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 ).

Drive Belt Tension Check (Refer to ).

Under Cover Installation (Refer to GROUP 51, Under Cover ).

Fuel Leak Check

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

			Removal steps
		23.	Alternator brace bolt
		24.	Detonation sensor connection
		25.	Battery wiring harness connection
		26.	Inlet manifold stay
		•	Water outlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
		•	Turbocharger assembly (Refer to GROUP 15, Exhaust Manifold and Turbocharger ).
		•	Rocker cover (Refer to ).
		27.	Heater water hose connection
		28.	Fuel return line hose connection
	>>C<<	29.	Fuel high-pressure hose connection
	>>C<<	30.	O-ring
<<A>>	>>B<<	31.	Cylinder head bolts
		32.	Cylinder head assembly
	>>A<<	33.	Cylinder head gasket

REMOVAL SERVICE POINT

<<A>> 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.

NOTE: 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.

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" 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