External Components

IGNITION SYSTEM





Removal
Follow removal steps outlined in illustration.

The electronic ignition coil pack attaches to the cylinder head cover.
1. Disconnect electrical connector from coil pack.
2. Remove coil pack mounting nuts.
3. Remove coil.
4. Remove spark plug cables.
5. Remove the spark plug using a quality socket with a rubber or foam insert.
6. Inspect the spark plug condition.





7. Remove camshaft position sensor mounting screws on the rear of the cylinder head. Remove sensor.





8. Loosen screw attaching target magnet to rear of camshaft.




9. Remove crankshaft position sensor mounting screw. Remove sensor.

Installation
Installation in reverse order as removal.
1. Install crankshaft position sensor.





2. The target magnet has locating dowels that fit into off-set machined locating holes in the end of the camshaft. Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (2.2 ft. lbs.) torque.
3. Install camshaft position sensor. Tighten sensor mounting screws to 9 Nm (6.5 ft. lbs.) torque.
4. To avoid cross threading, start the spark plug into the cylinder head by hand.
5. Tighten spark plugs to 28 Nm (20 ft. lbs.) torque.
6. Install spark plug insulators over spark plugs. Ensured the top of the spark plug insulator seals the upper end of the spark plug tube.





7. Install ignition coil pack. Connect spark plug cables to coil pack. The coil pack towers are numbered with the cylinder identification.

Inspection
Spark Plug Cable
1. Resistance must be between 3,000 to 12,000 ohms per foot of cable. Replace any cable not within tolerance.

Ignition Coil





1. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B + pin and the pin corresponding to the cylinders in question. Resistance on the primary side of each coil should be 0.51 - 0.61 ohms. Replace the coil if resistance is not within tolerance.





2. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance of the coil between the towers of each individual coil. Secondary resistance should be 11,500 - 13,500 ohms. Replace the coil if resistance is not within tolerance.

TIMING BELT

Removal

CAUTION: Camshaft or crankshaft should not be rotate after timing belt is removed. Damage to valve components may occur. Always align timing marks before removing timing belt.





1. Remove crankshaft damper bolt. Remove damper using Special Tool MB995055 and insert MB995057 or equivalent.





2. Remove engine mount bracket.





3. Remove front half of timing bell cover.





4. Align timing marks. Loosen timing belt tensioner screws and remove timing belt.
5. Remove tensioner pulley
6. Remove timing belt tensioner.
7. Remove tensioner arm bracket.
8. Remove idler pulley.





9. When tensioner is removed from the engine, it is necessary to compress the plunger into the tensioner body.
10. Place the tensioner into a vise and slowly compress the plunger.

CAUTION: Index the tensioner in the vise the same way it is installed on the engine. This is to ensure proper pin orientation when tensioner is installed on the engine.

11. When plunger is compressed into the tensioner body, install a pin through the body and plunger to retain plunger in place until tensioner is installed.





12. Hold camshaft sprocket with Special Tools MB990767 and MD998719 while removing bolt.
13. Remove support bracket.





14. Remove rear timing belt cover fasteners. Remove cover.





15. Remove camshaft seal.

Installation





1. Install camshaft seal into cylinder head using Special Tool MD998713 until flush with the head.

NOTE: Shaft seal lip surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary.





2. Install rear timing belt cover. Tighten fasteners to 9.6 Nm (6.9 ft. lbs.).
3. Install support bracket.





4. Install camshaft sprockets and tighten attaching bolts to 101 Nm (73 ft. lbs.).
5. Install idler pulley.
6. Install tensioner arm bracket.
7. Install timing belt tensioner.
8. Install tensioner pulley.





9. Set crankshaft sprocket to TDC by aligning the sprocket with the arrow on the oil pump housing.





10. Set camshafts timing marks together by aligning notches on sprockets.
11. Move crankshaft to 1/2 notch before TDC.





12. Install timing belt. Starting at the crankshaft, go around the water pump sprocket, idler pulley, camshaft sprockets and then around the tensioner pulley.
13. Move crankshaft sprocket to TDC to take up belt slack. Install tensioner to block but do not tighten fasteners.
14. Using a torque wrench on the tensioner pulley, apply 28 Nm (20 ft. lbs.) of torque to tensioner.





15. With torque being applied to the tensioner pulley move the tensioner up against the tensioner pulley bracket and tighten fasteners to 31 Nm (22 ft. lbs.).
16. Pull tensioner plunger pin. Pretension is correct when pin can- be removed and installed.
17. Rotate crankshaft 2 revolutions and check the alignment of the timing marks.





18. Install front timing belt cover.





19. Valve Timing Check; (timing belt cover installed), remove the inspection cover on timing belt cover. With number one cylinder at TDC, the timing marks on the camshaft sprocket should be aligned together. If marks are not aligned correctly, perform procedure again.





20. Install engine mount bracket. Tighten bolts to 41 Nm (30 ft. lbs.).





21. Install crankshaft damper using MB995035.
Using Special fools MB990767 and MD998719 to hold damper, tighten crankshaft bolt to 62 Nm (45 ft. lbs.).

FUEL AND EMISSION CONTROL PARTS

Removal
Follow removal steps outlined in illustration.





1. Remove screws attaching EGR tube to intake manifold.





2. Remove EGR valve mounting screws. Remove EGR valve and transducer.





3. Disconnect purge hose from throttle body.
4. Remove throttle body mounting bolts. Remove throttle body.
5. Remove gaskets. Clean gasket mating surfaces.
6. Release fuel system pressure. Refer to Fuel System Pressure Release procedure in this section.
7. Remove fuel rail mounting screws. Access screws through the space between the intake manifold plenum runners.





8. Lift rail off of intake manifold. Cover the fuel injector openings in the intake manifold.
9. Remove fuel injector retainer.
10. Pull injector out of fuel rail. Replace fuel injector O-rings.

Installation
Installation in reverse order as removal.

1. Apply a light coating of clean engine oil to the upper O-ring.
2. Install injector in cup on fuel rail.
3. Install retaining clip.
4. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
5. Insert fuel injector nozzle into openings in intake manifold. Seat the injectors in place. Tighten fuel rail mounting screws.
6. Connect fuel supply tube to fuel rail.
7. Install throttle body and new gasket on intake manifold. Tighten mounting bolts.





8. Connect purge hose nipple on throttle body.
9. Loosely install EGR valve with a new gasket. Install new gasket between EGR tube and EGR valve.
10. Finger tighten EGR tube fasteners.
11. Tighten EGR valve mounting screws to 2 Nm (16 ft. lbs.), torque.
12. Tighten EGR tube fasteners to 11 Nm (8 ft. lbs.) torque.
13. Connect vacuum supply tube to solenoid.

INTAKE MANIFOLD

Removal
Follow removal steps outlined in illustration.

1. Remove intake air temperature sensor.





2. Remove manifold absolute pressure (MAP) sensor mounting screws.
3. Remove (MAP) sensor.





4. Remove intake manifold stay.
5. Remove EGR tube fasteners from the intake manifold and valve. Remove tube from engine.
6. Remove vacuum hose and electrical connection from intake manifold.
7. Remove attaching screws from engine and remove intake manifold from engine.

Cleaning And Inspection

1. Discard gasket and clean gasket surfaces of manifold.
2. Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm of manifold length.
3. Inspect manifold for cracks or distortion. Replace manifold if necessary.

Installation
Installation in reverse order as removal.





1. Install new manifold gasket. Do Not Apply Sealer.
2. Set manifold in place. Tighten retaining fasteners, starting at center and progressing outward in both directions to 23 Nm (17 ft. lbs). Repeat this procedure until all fasteners are at specified torque.
3. Install vacuum hose and electrical connection from intake manifold.
4. Install new EGR tube gaskets at the intake manifold and valve.
5. Install EGR tube and tighten fasteners to 8 Nm (6 ft. lbs.).
6. Install intake manifold stay.





7. Insert sensor into intake manifold while making sure not to damage O-ring seals.
8. Tighten mounting screws to 2 Nm (1.4 ft. lbs.) torque.
9. Install manifold air temperature sensor. Tighten sensor to 7 Nm (5 ft. lbs.) torque.

EXHAUST MANIFOLD

Removal
Follow removal steps outlined in illustration.





1. Remove oil level gauge.
2. Remove exhaust manifold heat shield.
3. Remove 8 exhaust manifold retaining fasteners and remove exhaust manifold.

Installation
Installation in reverse order as removal.





1. Install new manifold gasket. Do Not Apply Sealer.
2. Set exhaust manifold in place. Tighten retaining nuts and bolt, starting at center and progressing outward in both directions to 23 Nm (17 ft. lbs.) torque. Repeat this procedure until all fasteners are at specified torque.
3. Install exhaust manifold heat shield.
4. Install oil level gauge.

Cleaning And Inspection
1. Discard gasket and clean all gasket surfaces of manifolds and cylinder head.
2. Test manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 inch per foot) of manifold length.
3. Inspect manifolds for cracks or distortion. Replace manifold if necessary.