REMOVAL AND INSTALLATION


Pre-removal Operation
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • 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 ).
  • Engine Cover Removal (Refer to ).
  • Air Cleaner Assembly and Air Intake Duct Removal (Refer to GROUP 15 - Air Cleaner ).
  • Radiator Shroud Cover and Radiator Shroud Removal (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Cooling Fan Clutch Assembly Removal (Refer to GROUP 14 - Cooling Fan ).
  • A/C Compressor Drive Belt and Alternator Drive Belt Removal (Refer to ).
  • EGR Cooler Assembly and EGR Cooler Bracket Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Except for Euro 5>.
  • EGR Cooler Assembly and EGR Cooler Bracket Removal (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Euro 5>.
  • Turbocharger Assembly and Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ) <HIGH POWER>.
  • Turbocharger Assembly and Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold and Turbocharger ) <Except for HIGH POWER>.
  • Thermostat Removal (Refer to GROUP 14 - Thermostat ).
  • Vacuum Pipe Assembly, Heater Hose, Heater Return Pipe and Thermostat Case Removal (Refer to GROUP 14 - Water Hose and Water Pipe ) <Except for Euro 5>.
  • Vacuum Pipe Assembly, Heater Hose, Heater Return Pipe and Thermostat Case Removal (Refer to GROUP 14 - Water Hose and Water Pipe ) <Euro 5>.
  • Throttle Body Assembly Removal (Refer to GROUP 13B - Throttle Body Assembly ).
  • Air Inlet Pipe and Inlet Manifold Assembly Removal (Refer to GROUP 15 - Inlet Manifold ) <Except for Euro 5>.
  • Air Inlet Pipe and Inlet Manifold Assembly Removal (Refer to GROUP 15 - Inlet Manifold ) <Euro 5>.
  • Fuel Injector Assembly and Common Rail Assembly Removal (Refer to GROUP 13B - Fuel Injector and Common Rail ).
  • Camshaft Assembly and Rocker Arm Removal (Refer to ).
  • Engine Oil Pipe Removal (Refer to ).

 Post-installation Operation
  • Engine Oil Pipe Installation (Refer to ).
  • Camshaft Assembly and Rocker Arm Installation (Refer to ).
  • Fuel Injector Assembly and Common Rail Assembly Installation (Refer to GROUP 13B - Fuel Injector and Common Rail ).
  • Air Inlet Pipe and Inlet Manifold Assembly Installation (Refer to GROUP 15 - Inlet Manifold ) <Except for Euro 5>.
  • Air Inlet Pipe and Inlet Manifold Assembly Installation (Refer to GROUP 15 - Inlet Manifold ) <Euro 5>.
  • Throttle Body Assembly Installation (Refer to GROUP 13B - Throttle Body Assembly ).
  • Vacuum Pipe Assembly, Heater Hose, Heater Return Pipe and Thermostat Case Installation (Refer to GROUP 14 - Water Hose and Water Pipe ) <Except for Euro 5>.
  • Vacuum Pipe Assembly, Heater Hose, Heater Return Pipe and Thermostat Case Installation (Refer to GROUP 14 - Water Hose and Water Pipe ) <Euro 5>.
  • Thermostat Installation (Refer to GROUP 14 - Thermostat ).
  • Turbocharger Assembly and Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold and Turbocharger Assembly ) <HIGH POWER>.
  • Turbocharger Assembly and Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold and Turbocharger Assembly ) <Except for HIGH POWER>.
  • EGR Cooler Assembly and EGR Cooler Bracket Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Except for Euro 5>.
  • EGR Cooler Assembly and EGR Cooler Bracket Installation (Refer to GROUP 17 - EGR Valve and EGR Cooler ) <Euro 5>.
  • Cooling Fan and Cooling Fan Clutch Assembly Installation (Refer to GROUP 14 - Cooling Fan ).
  • A/C Compressor Drive Belt and Alternator Drive Belt Installation (Refer to ).
  • Radiator Shroud Cover and Radiator Shroud Installation (Refer to GROUP 14 - Radiator ).
  • Air Cleaner Assembly and Air Intake Duct Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Cover Installation (Refer to ).
  • 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 ).
  • Drive Belt Tension Check and Adjustment (Refer to ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Fuel line Air-bleeding (Refer to GROUP 13B - On-vehicle Service, Evacuation of Air From Fuel Line ).
  • Under Skid Plate and Engine Room Under Cover (Front) Installation (Refer to GROUP 51 - Under Cover ).

<HIGH POWER>

Removal steps
<<A>>
 >>B<<
 1.
 Radiator upper hose connection
<<B>>
 >>A<<
 2.
 Cylinder head assembly
<<B>>
 >>A<<
 3.
 Cylinder head gasket

<Except for HIGH POWER>

Removal steps
<<A>>
 >>B<<
 1.
 Radiator upper hose connection
<<B>>
 >>A<<
 2.
 Cylinder head assembly
<<B>>
 >>A<<
 3.
 Cylinder head gasket

REMOVAL SERVICE POINTS

<<A>> RADIATOR UPPER HOSE DISCONNECTION

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

<<B>> CYLINDER HEAD ASSEMBLY/CYLINDER HEAD GASKET REMOVAL

1.Loosen the cylinder head bolts in the shown sequence progressively, and then remove the cylinder head bolts.
2.Lift the cylinder head assembly and cylinder head gasket straight without removing the timing chain from the camshaft sprocket.

3.After the cylinder head assembly and cylinder head gasket has been removed, use special tool camshaft sprocket holder kit (MH063490) to hold the camshaft sprocket to prevent the timing chain from sliding off.

  • A: Nut
  • B: Washer
  • C: Spacer
  • D: Adjusting plate
  • E: Flange bolt
  • F: Flange bolt
  • G: Nut

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION

1.
caution The thickness of the original cylinder head gasket is selected according to the protrusion amount of the piston. Therefore, if the cylinder block, piston, connecting rod or crankshaft is replaced, the protrusion amount may be changed. Always select a correct gasket by measuring the protrusion amount. (Refer to GROUP 11D - Cylinder Head and Valves ).
To replace the cylinder head gasket only, select a gasket of correct specification according to the table below.

<High power>
Notch specification (fitted thickness mm)
 Part number
A (0.70 ± 0.04)
 1005B762
B (0.75 ± 0.04)
 1005B763
C (0.80 ± 0.04)
 1005B764
D (0.85 ± 0.04)
 1005B765

<Except for High power>
Notch specification (fitted thickness mm)
 Part number
A (0.70 ± 0.04)
 1005B222
B (0.75 ± 0.04)
 1005B223
C (0.80 ± 0.04)
 1005B224
D (0.85 ± 0.04)
 1005B225
2.
caution Do not allow foreign material to enter the engine coolant or oil passages and the cylinder.
Clean the cylinder head assembly, timing gear case assembly, front plate assembly and crankcase assembly matching surfaces with a scraper or a wire brush.

3.Apply the specified sealant to the matching surface of the front plate assembly and cylinder head gasket.
Specified sealant: ThreeBond 1207F
note Install the cylinder head gasket and cylinder head assembly immediately after applying sealant.
4.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
Install the cylinder head gasket and cylinder head assembly to the crankcase assembly.

5.
caution The cylinder head bolts can be reused up to 3 times. Therefore, the cylinder head bolts with 3 punch marks already applied must be replaced with new cylinder head bolts.
Apply punch marks to the bolt heads of the cylinder head bolts.

6.Install the cylinder head bolt washer to the cylinder head bolt so that the washer chamfered side faces as shown.
7.Apply a small amount of engine oil to the cylinder head bolt thread and the washer.



8.Tighten the cylinder head bolts according to the following procedure (angle-tightening procedure).
(1) Tighten the bolts to 98 ± 10 N·m in the order shown.
Bolt size: Nominal diameter × length mm

    <Except 3, 6, 11, 14>: 12 × 118
    <3, 6, 11, 14>: 12 × 133
(2) Loosen the bolts fully in the reverse sequence to that shown.
(3) Tighten the bolts to 49 ± 5 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 degree angle 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 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.
(6) Apply a small amount of engine oil to the thread and the flange of bolts A, and tighten them to A to 58 ± 6 N·m.

>>B<< RADIATOR UPPER HOSE CONNECTION

1.Insert the radiator upper hose as far as the projection of the cooling water outlet pipe.
2.Align the matching marks on the radiator upper hose and hose clamp, and then connect the radiator upper hose.