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 ).
  • Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).
  • Inlet Manifold Removal (Refer to GROUP 15, Inlet Manifold ).
  • Water Pump Inlet Pipe Removal (Refer to GROUP 14, Water Hose and Water Pipe ).
  • Ignition Coil Removal (Refer to GROUP 16, Ignition System - Ignition Coil ).
  • Valve Timing Belt Removal (Refer to ).
  • Rocker Cover Assembly Removal (Refer to ).

 Post-installation Operation
  • Rocker Cover Assembly Installation (Refer to ).
  • Valve Timing Belt Installation (Refer to ).
  • Ignition Coil Installation (Refer to GROUP 16, Ignition System - Ignition Coil ).
  • Water Pump Inlet Pipe Installation (Refer to GROUP 14, Water Hose and Water Pipe ).
  • Inlet Manifold Installation (Refer to GROUP 15, Inlet Manifold ).
  • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).
  • Fuel Leak Check




Removal steps


·
 Engine mounting insulator (Refer to GROUP 32, Engine Mounting ).


1.
 Noise condenser


2.
 Heater hose connection


·
 Alternator brace (Refer to GROUP 16, Charging System - Alternator Assembly ).


3.
 Eye bolt


4.
 Gasket


5.
 Eye bolt


6.
 Gasket


7.
 Oil feeder control valve pipe

>>C<<
 8.
 Oil feeder control valve filter
<<A>>
 >>B<<
 9.
 Cylinder head bolts


10.
 Cylinder head assembly

>>A<<
 11.
 Cylinder head gasket

REMOVAL SERVICE POINT

<<A>> CYLINDER HEAD BOLTS REMOVAL

Use special tool cylinder head bolt wrench (MB991653) to 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
1.
caution Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
Degrease the cylinder head gasket mounting surface.

2.Assemble to the cylinder block so the cylinder head gasket identification mark of "1.5" is at the top surface and on the inlet side.

>>B<< CYLINDER HEAD BOLTS INSTALLATION

1.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): 103.2 mm
2.Apply a small amount of engine oil to the thread of the bolts and to the washers.


3.Use special tool cylinder head bolt wrench (MB991653) to tighten the cylinder head bolts in the following procedures.
(1) Tighten the bolts to 49 ± 2 N·m in the order shown.
(2) Loosen the bolts fully in the reverse sequence to that shown.
(3) Tighten the bolts to 20 ± 2 N·m in the order shown.
(4) Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90° as shown.
(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.
Tighten in a 90° 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<< OIL FEEDER CONTROL VALVE FILTER INSTALLATION
caution Check the oil feeder control valve filter for adhesion of foreign materials, damage or deformation before installation.