REMOVAL AND INSTALLATION

Pre-removal Operation

Fuel Line Pressure Reduction [Refer to GROUP 13C, 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 ).

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

Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal ) <L.H. drive vehicles>.

Post-installation Operation

Accelerator Cable Installation (Refer to GROUP 17, Accelerator Cable and Pedal ) <L.H. drive vehicles>.

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

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

Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service - Accelerator Cable Check and Adjustment ) <L.H. drive vehicles>.

Fuel Leak Check

			Removal steps
		1.	Control wiring harness connection
		2.	Battery wiring harness connection
		3.	Radiator lower hose clamp
		4.	Canister vacuum hose connection
		5.	Brake booster vacuum hose connection
		6.	Engine oil level gauge and guide assembly
		7.	O-ring

			Removal steps
		8.	Detonation sensor connection
		9.	Battery wiring harness connection
		10.	Inlet manifold stay
		•	Exhaust manifold (Refer to GROUP 15, Exhaust Manifold ).
		•	Timing belt upper cover (Refer to ).
<<A>>	>>E<<	11.	Camshaft sprocket
<<B>>	>>D<<	12.	Radiator upper hose connection
		13.	Water hose connection
		•	Water inlet fitting and thermostat case assembly (Refer to GROUP 14, Water Hose and Water Pipe ).
<<C>>	>>C<<	14.	Fuel high-pressure hose connection
		•	Rocker cover assembly (Refer to ).
<<D>>	>>B<<	15.	Cylinder head bolts
		16.	Cylinder head assembly
	>>A<<	17.	Cylinder head gasket

REMOVAL SERVICE POINTS

<<A>> 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 special tool adjusting bolt (MD998738).

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 and so on to prevent slippage between the camshaft sprocket and valve timing belt.

Use the following special tools to hold the camshaft sprocket.

Front hub and flange yoke holder (MB990767)

Pin (MD998719)

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.

<<B>> RADIATOR UPPER HOSE DISCONNECTION

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

<<C>> FUEL HIGH-PRESSURE HOSE DISCONNECTION

Remove the fuel high-pressure hose stopper.

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.

<<D>> CYLINDER HEAD BOLTS REMOVAL

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.

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET INSTALLATION

CAUTION

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

Degrease the cylinder head gasket mounting surface.

Assemble to the cylinder block so the cylinder head gasket identification mark of "381" 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 bolts 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 in the following procedures.

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

Loosen the bolts fully in the reverse sequence to that shown.

Tighten the 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 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.

>>C<< FUEL HIGH-PRESSURE HOSE CONNECTION

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.

>>D<< RADIATOR UPPER HOSE CONNECTION

Insert radiator upper hose until it contacts the projection on the water outlet fitting.

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

>>E<< CAMSHAFT SPROCKET INSTALLATION

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

Front hub and flange yoke holder (MB990767)

Pin (MD998719)

Tighten the camshaft sprocket mounting bolt to the specified torque.

Tightening torque: 89 ± 9 N·m