三菱montero维修手册v7504英文gr 11a

11A-1

GROUP11A

ENGINEMECHANICAL

CONTENTS

GENERALDESCRIPTION.........

11A-2

REMOVALANDINSTALLATION........

11A-23

OILPANANDOILSCREEN.......

REMOVALANDINSTALLATION........

INSPECTION........................

11A-26

11A-26

11A-28

ENGINEDIAGNOSIS.............

11A-2

SPECIALTOOLS................

11A-4

CRANKSHAFTOILSEAL.........

REMOVALANDINSTALLATION

<FRONTOILSEAL>..................

REMOVALANDINSTALLATION

<REAROILSEAL>...................

11A-28

ON-VEHICLESERVICE...........

DRIVEBELTTENSIONCHECK.........

AUTO-TENSIONERCHECK...........

IGNITIONTIMINGCHECK.............

CURBIDLESPEEDCHECK...........

IDLEMIXTURECHECK...............

COMPRESSIONPRESSURECHECK....

MANIFOLDVACUUMCHECK..........

LASHADJUSTERCHECK.............

11A-7

11A-7

11A-7

11A-7

11A-8

11A-9

11A-10

11A-11

11A-12

11A-28

11A-30

CYLINDERHEADGASKET........

REMOVALANDINSTALLATION........

11A-32

11A-32

TIMINGBELT...................

REMOVALANDINSTALLATION........

INSPECTION........................

11A-36

11A-36

11A-43

ENGINEASSEMBLY.............

REMOVALANDINSTALLATION........

11A-15

11A-15

SPECIFICATIONS...............

FASTENERTIGHTENINGSPECIFICATIONS....................

SERVICESPECIFICATIONS...........

LUBRICANT........................

SEALANTS.........................

11A-44

CAMSHAFTANDVALVESTEMSEAL.........................

REMOVALANDINSTALLATION........

11A-18

11A-18

11A-44

11A-45

11A-45

11A-45

CAMSHAFTOILSEAL...........

11A-23

11A-2

ENGINEMECHANICAL

GENERALDESCRIPTION

GENERALDESCRIPTION

M1111000100527

The6G75(3.8L)engineisasix-cylinderengine.Thecylindernumbersareassignedas1-3-5fortherightbankand2-4-6fortheleftbankfromthefrontoftheengine(timingbeltside).Thisengineisfiredintheorderof1-2-3-4-5-6cylinders.

ENGINEDIAGNOSIS

M1111000700295

TSBRevision

SYMPTOMS

PROBABLECAUSE

REMEDY

Compressionistoolow

Blowncylinderheadgasket

Replacethegasket.

Wornordamagedpistonrings

Replacetherings.

Wornpistonorcylinder

Repairorreplacethepistonand/orthecylinderblock.

Wornordamagedvalveseat

Repairorreplacethevalveand/ortheseatring

Dropinengineoilpressure

Engineoillevelistoolow

Checktheengineoillevel.

Malfunctionofengineoilpressureswitch

Replacetheengineoilpressureswitch.

Cloggedoilfilter

Installanewfilter.

Wornoilpumpgearsorcover

Replacethegearsand/orthecover.

Thinordilutedengineoil

Changetheengineoiltothecorrectviscosity.

Stuck(opened)oilreliefvalve

Repairthereliefvalve.

Excessivebearingclearance

Replacethebearings.

Engineoilpressuretoohigh

Stuck(closed)oilreliefvalve

Repairthereliefvalve.

ITEMS

SPECIFICATIONS

Type

Vtype,overheadcamshaft

Numberofcylinders

6

Boremm(in)

95.0(3.74)

Strokemm(in)

90.0(3.54)

Totaldisplacementcm3(cu.in)

3,828(233.6)

Compressionratio

10.0

Firingorder

1-2-3-4-5-6

Valvetiming

Intakevalve

Opens(BTDC)

5

Closes(ABDC)

55

Exhaustvalve

Opens(BBDC)

51

Closes(ATDC)

17

Lubricationsystem

Pressurefeed,full-flowfiltration

Oilpumptype

Trochoidtype

11A-3

ENGINEMECHANICAL

ENGINEDIAGNOSIS

TSBRevision

SYMPTOMS

PROBABLECAUSE

REMEDY

Noisyvalves

Malfunctionoflashadjuster(includingentryofairintohighpressurechamber)

Checkthelashadjuster.

Thinordilutedengineoil(lowengineoilpressure)

Changetheengineoil.

Wornordamagedvalvestemorvalveguide

Replacethevalveand/ortheguide.

Connectingrodnoise/mainbearingnoise

Insufficientoilsupply

Checktheengineoillevel.

Thinordilutedengineoil

Changetheengineoil.

Excessivebearingclearance

Replacethebearings.

11A-4

ENGINEMECHANICAL

SPECIALTOOLS

SPECIALTOOLS

M1111000600630

TSBRevision

TOOL

TOOLNUMBERANDNAME

SUPERSESSION

APPLICATION

MB991958

Scantool(MUT-IIIsubassembly)

A:MB991824

Vehiclecommunicationinterface(V.C.I.)

B:MB991827

MUT-IIIUSBcableC:MB991910

MUT-IIImainharnessA(VehicleswithCANcommunicationsystem)

D:MB991911

MUT-IIImainharnessB(VehicleswithoutCANcommunicationsystem)

E:MB991914

MUT-IIImainharnessC(forDaimlerChryslermodelsonly)

F:MB991825

MUT-IIImeasurementadapter

G:MB991826

MUT-IIItriggerharness

MB991824-KIT

NOTE:G:MB991826

MUT-IIItriggerharnessisnotnecessarywhenpushingV.C.I.ENTERkey.

Drivebelttensioncheck

Ignitiontimingcheck

Curbidlespeedcheck

Idlemixturecheck

MUT-IIImainharnessB(MB991911)shouldbeused.MUT-IIImainharnessAandCshouldnotbeusedforthisvehicle.

B991668

MB991668

Belttensionmeterset

Toolnotavailable

Measurementofdrivebelttension(usedtogetherwithscantool<MUT-IIISubAssembly>)

CAUTION

A

MB991824

B

MB991827

C

MB991910

D

MB991911

E

MB991914

F

MB991825

G

MB991826

MB991958

DONOTUSE

DONOTUSE

11A-5

ENGINEMECHANICAL

SPECIALTOOLS

TSBRevision

TOOL

TOOLNUMBERANDNAME

SUPERSESSION

APPLICATION

B991683

MB991683

Slingchainset

Toolnotavailable

Removalandinstallationofengineassembly

B990767

MB990767

Endyokeholder

MB990767-01

Holdingthecamshaftsprocket

MD998715

Crankshaftpulleyholderpin

MIT308239

Holdingthecamshaftsprocket

D998443

MD998443

Auto-lashadjusterholder

MD998443-01

Holdingtheauto-lashadjuster

AC204024

MD998772

Valvespringcompressor

Generalservicetool

Compressingvalvespring

MD998774

Valvestemsealinstaller

MD998774-01

Valvestemsealinstaller

D998713

MD998713

Camshaftoilsealinstaller

MD998713-01

Press-inofthecamshaftoilseal

B991559

MB991559

Camshaftoilsealadapterinstaller

Toolnotavailable

Press-fittingthecamshaftoilseal(leftbankside)

11A-6

ENGINEMECHANICAL

SPECIALTOOLS

TSBRevision

TOOL

TOOLNUMBERANDNAME

SUPERSESSION

APPLICATION

MD998717

Crankshaftfrontoilsealinstaller

MD998717-01

Press-inofthecrankshaftfrontoilseal

D998781

MD998781

Flywheelstopper

Generalservicetool

Securingthedriveplate

MD998718

Crankshaftrearoilsealinstaller

MD998718-01

Press-fittingthecrankshaftrearoilseal

MD998051

Cylinderheadboltwrench

MD998051-01orGeneralservicetool

Cylinderheadboltremovalandinstallation

MB991800

MB991800

Pulleyholder

MB991800-01

Holdingthecrankshaftpulley

MB991802

MB991802

PinB

MB991802-01

Holdingthecrankshaftpulley

MD998767

Tensionpulleysocketwrench

MD998752-01

Timingbelttensionadjustment

MD998769

Crankshaftpulleyspacer

Generalservicetool

Rotatingthecrankshaftwheninstallingthetimingbelt

D998767

11A-7

ENGINEMECHANICAL

ON-VEHICLESERVICE

ON-VEHICLESERVICE

DRIVEBELTTENSIONCHECK

M1111003100571

RefertoGROUP00,MaintenanceServiceDriveBelts(CheckCondition)P.00-41.

AUTO-TENSIONERCHECK

M1111003000035

1.

Runtheengineatidlingspeedandthenstopittocheck

whetherthedrivebeltiscenteredontheauto-tensionerpulley.

Inserta1/2inchbreakerbarintothesquareholeonthedrivebeltautotensioner,androtateitclockwiseuntilthetensionertouchesthestopper.

AlignholeBwithholeA,andinserta5.0mm(0.20inch)Allenwrenchtoholdthetensioner.Thenloosenthedrivebelt,andthenremovethedrivebeltautotensioner.

Movetheauto-tensionerrightandleftbyusinga1/2inchbreakerbarorsimilartooltoverifythatitmovessmoothly.Ifsomeabnormalityisfoundduringtheabovementionedcheck(1)and(3),replacetheauto-tensioner.

2.

3.

4.

5.

IGNITIONTIMINGCHECK

RequiredSpecialTool:

MB991958:ScanTool(MUT-IIISubAssembly)

MB991824:V.C.I.

MB991827:MUT-IIIUSBCable

MB991911:MUT-IIIMainHarnessB

1.Beforechecks,setthevehicleinthefollowingcondition:

Enginecoolanttemperature:8095C(176203F)

Lightsandallaccessories:OFF

Transmission:Prange

NOTE:VehiclesforCanada,theheadlight,taillight,etc.remainlitevenwhenthelightingswitchisin"OFF"positionbutthisisnoproblemforchecks.

M1111001700533

TSBRevision

CLOCKWISE

HOLEB

HOLEA

SQUAREHOLE

ALLENWRENCH

ACX01424AB

11A-8

ENGINEMECHANICAL

ON-VEHICLESERVICE

TopreventdamagetoscantoolMB991958,alwaysturntheignitionswitchtothe"LOCK"(OFF)positionbeforecon-nectingordisconnectingscantoolMB991958.

2.

3.

4.

5.

6.

7.

ConnectscantoolMB991958tothedatalinkconnector.Setupatiminglight.

Starttheengineandrunitatidle.

Checkthattheidlespeedisapproximately700r/min.SelectscantoolMB991958actuatortest"itemnumber17".Checkthatbasicignitiontimingiswithinthestandardvalue.

Standardvalue:5BTDC3

Ifthebasicignitiontimingisnotwithinthestandardvalue,

8.

checkthefollowingitems:

Diagnosticoutput

Timingbeltcoverandcrankshaftpositionsensorinstallationconditions

Crankshaftsensingbladecondition

Iftheactuatortestisnotcanceled,theforceddrivewillcontinuefor27minutes.Drivinginthisstatecouldleadtoenginefailure.

PresstheclearkeyonscantoolMB991958(selectforceddrivestopmode),andcanceltheactuatortest.

Checkthattheactualignitiontimingisatthestandardvalue.

Standardvalue:Approximately10BTDC

NOTE:Ignitiontimingfluctuatesabout7BeforeTopDeadCenter,evenundernormaloperatingcondition.

NOTE:Itisautomaticallyfurtheradvancedbyabout5to10BeforeTopDeadCenterathigheraltitudes.

CURBIDLESPEEDCHECK

RequiredSpecialTool:

MB991958:ScanTool(MUT-IIISubAssembly)

MB991824:V.C.I.

MB991827:MUT-IIIUSBCable

MB991911:MUT-IIIMainHarnessB

1.Beforechecks,setthevehicleinthefollowingcondition.

Enginecoolanttemperature:8095C(176203F)

Lightsandallaccessories:OFF

Transmission:Prange

NOTE:VehiclesforCanada,theheadlight,taillight,etc.remainlitevenwhenthelightingswitchisin"OFF"positionbutthisisnoproblemforchecks.

M1111003500580

TSBRevision

CAUTION

MB991911

MB991824

MB991827

AK302970AB

CAUTION

11A-9

ENGINEMECHANICAL

ON-VEHICLESERVICE

TopreventdamagetoscantoolMB991958,alwaysturntheignitionswitchtothe"LOCK"(OFF)positionbeforecon-nectingordisconnectingscantoolMB991958.

2.

3.

ConnectscantoolMB991958tothedatalinkconnector.Checkthebasicignitiontiming.

Standardvalue:5BTDC3

Starttheengine.

Runtheengineatidlefor2minutes.

Checktheidlespeed.Selectitemnumber22andtakeareadingoftheidlespeed.

Curbidlespeed:700100r/min

NOTE:Theidlespeediscontrolledautomaticallybytheidleaircontrolsystem.

Iftheidlespeedisoutsidethestandardvalue,refertoGROUP13A,MultiportFuelInjection(MFI)MultiportFuelInjection(MFI)DiagnosisSymptomChartP.13A-30.

4.

5.

6.

7.

IDLEMIXTURECHECK

RequiredSpecialTool:

MB991958:ScanTool(MUT-IIISubAssembly)

MB991824:V.C.I.

MB991827:MUT-IIIUSBCable

MB991911:MUT-IIIMainHarnessB

1.Beforechecks,setthevehicleinthefollowingcondition:

Enginecoolanttemperature:8095C(176203F)

Lightsandallaccessories:OFF

Transmission:Prange

NOTE:VehiclesforCanada,theheadlight,taillight,etc.remainlitevenwhenthelightingswitchisin"OFF"positionbutthisisnoproblemforchecks.

M1111002100352

TSBRevision

MB991911

MB991824

MB991827

AK302970AB

CAUTION

11A-10

ENGINEMECHANICAL

ON-VEHICLESERVICE

TopreventdamagetoscantoolMB991958,alwaysturntheignitionswitchtothe"LOCK"(OFF)positionbeforecon-nectingordisconnectingscantoolMB991958.

2.

3.

ConnectscantoolMB991958tothedatalinkconnector.Checkthatthebasicignitiontimingiswithinthestandardvalue.

Standardvalue:5BTDC3

Starttheengineandincreasetheenginespeedto2,500r/minfor2minutes.

SettheCO,HCtester.

ChecktheCOcontentsandtheHCcontentsatidle.

Standardvalue:

COcontents:0.5%orlessHCcontents:100ppmorless

IftheCOandHCcontentsdonotremaininsidethestandardvalue,checkthefollowingitems:

NOTE:ReplacethecatalyticconverterwhentheCOandHCcontentsdonotremaininsidethestandardvalue,eventhoughtheresultoftheinspectionisnormalforallitems.

Diagnosticoutput

Closed-loopcontrol(Whentheclosed-loopcontroliscarriedoutnormally,theoutputsignaloftheheatedoxygensensorchangesbetween0400mVand6001,000mVatidle.)Fuelpressures

Injector

Ignitioncoil,sparkplugcable,sparkplug

ExhaustgasrecirculationsystemandEGRvalveleakEvaporativeemissionsystem

Compressionpressure

4.

5.

6.

7.

COMPRESSIONPRESSURECHECK

M1111002600540

1.Beforechecks,checkthattheengineoil,starterandbatteryarenormal.Also,setthevehicleinthefollowingcondition:

Enginecoolanttemperature:8095C(176203F)

Lightsandallaccessories:OFF

Transmission:Prange

NOTE:VehiclesforCanada,theheadlight,taillight,etc.remainlitevenwhenthelightingswitchisin"OFF"positionbutthisisnoproblemforchecks.

Disconnectthesparkplugcables.

Removeallofthesparkplugs.

TSBRevision

MB991911

MB991824

MB991827

AK302970AB

CAUTION

11A-11

ENGINEMECHANICAL

ON-VEHICLESERVICE

4.Disconnectthecrankshaftpositionsensorconnector.

NOTE:Doingthiswillpreventtheenginecontrolmodulefromcarryingoutignitionandfuelinjection.

Keepyourdistancefromthesparkplugholewhencranking.Oil,fuel,etc.,maysprayoutfromthesparkplugholeandmaycauseseriousinjury.

CRANKSHAFTPOSITIONSENSORCONNECTOR

5.

Coverthesparkplugholewithashoptoweletc.,duringcranking.Aftertheenginehasbeencranked,checkforforeignmaterialadheringtotheshoptowel.

Setcompressiongaugetooneofthesparkplugholes.Cranktheenginewiththethrottlevalvefullyopenandmeasurethecompressionpressure.

Standardvalue(atenginespeedof250400r/min):1,548kPa(225psi)

Minimumlimit(atenginespeedof250400r/min):1,117kPa(162psi)

Measurethecompressionpressureforallthecylinders,andcheckthatthepressuredifferencesofthecylindersarebelowthelimit.

Limit:98kPa(14psi)

Ifthereisacylinderwithcompressionoracompressiondifferencethatisoutsidethelimit,pourasmallamountofengineoilthroughthesparkplughole,andrepeattheoperationsinsteps6to8.

Ifthecompressionincreasesafteroilisadded,thecauseofthemalfunctionisawornordamagedpistonringand/orcylinderinnersurface.

Ifthecompressiondoesnotriseafteroilisadded,thecauseisaburntordefectivevalveseat,orpressureisleakingfromthegasket.

AK200795AB

6.

7.

COMPRESSIONGAUGE

8.

AKX00436AB

9.

10.Connectthecrankshaftpositionsensorconnector.11.Installthesparkplugsandsparkplugcables.

12.Usethescantooltoerasethediagnostictroublecodes.

NOTE:Thiswillerasethediagnostictroublecoderesultingfromthecrankshaftpositionsensorconnectorbeingdiscon-nected.

MANIFOLDVACUUMCHECK

M1111002700495

1.Starttheengineandallowittowarmupuntilthe

temperatureoftheenginecoolantreaches8095C(176

203F).

2.Connectanenginetachometer.

TSBRevision

WARNING

11A-12

ENGINEMECHANICAL

ON-VEHICLESERVICE

Attachatee-fittinguniontothevacuumhosebetweenthefuelpressureregulatorandtheintakemanifoldplenum,andconnectavacuumgauge.

Starttheengineandcheckthatidlespeediswithinspecification.Thencheckthevacuumgaugereading.

Idlespeed:700100r/minMinimumlimit:60kPa(18inHg)

LASHADJUSTERCHECK

M1111002900411

Ifanabnormalnoise(chatteringnoise)suspectedtobecausedbymalfunctionofthelashadjusterisproducedimmediatelyafterstartingtheengineanddoesnotdisappear,performthefollowingcheck.

NOTE:Anabnormalnoiseduetomalfunctionofthelashadjusterisproducedimmediatelyafterstartingtheengineandchangeswiththeenginespeed,irrespectiveoftheengineload.If,theabnormalnoiseisnotproducedimmediatelyafterstart-ingtheengineordoesnotchangewiththeenginespeed,oritchangeswiththeengineload,thelashadjusterisnotthecausefortheabnormalnoise.

NOTE:Whenthelashadjusterismalfunctioning,theabnormalnoiseisrarelyeliminatedbycontinuingthewarming-upoftheengineatidlespeed.

However,theabnormalnoisemaydisappearonlywhenseizureiscausedbyoilsludgeintheenginewhoseoilisnotmain-tainedproperly.

1.

2.

Starttheengine.

Checkiftheabnormalnoiseproducedimmediatelyafterstartingtheengine,changeswiththechangeintheenginespeed.

Iftheabnormalnoiseisnotproducedimmediatelyafterstartingtheengineoritdoesnotchangewiththeenginespeed,thelashadjusterisnotthecauseforthenoise.Therefore,investigateothercauses.Theabnormalnoiseisprobablycausedbysomeotherpartsthantheengineproperifitdoesnotchangewiththeenginespeed.(Inthiscase,thelashadjusterisingoodcondition.)

Withtheengineidling,changetheengineload(shiftfromNtoDrange,forexample)tomakesurethatthereisnochangeinthelevelofabnormalnoise.

Ifthereisachangeinthelevelofabnormalnoise,suspectatappingnoiseduetoworncrankshaftbearingorconnectingrodbearing(Inthiscase,thelashadjusterisingoodcondition.).

Aftercompletionofwarm-up,runtheengineatidletocheckforabnormalnoise.

3.

4.

TSBRevision

VACUUMGAUGE AK200796AB

11A-13

ENGINEMECHANICAL

ON-VEHICLESERVICE

Ifthenoiseisreducedordisappears,cleanthelashadjuster(RefertoGROUP11B,EngineOverhaulRockerArmsandCamshaftInspectionP.11B-25).Asitissuspectedthatthenoiseisduetoseizureofthelashadjuster.Ifthereisnochangeintheleveloftheabnormalnoise,proceedtostep5.

5.

Runtheenginetobleedthelashadjustersystem(RefertoP.11A-12.).

Iftheabnormalnoisedoesnotdisappearafterairbleedingoperation,cleanthelashadjuster(RefertoGROUP11B,EngineOverhaulRockerArmsandCamshaftInspectionP.11B-25).

6.

Bleedinglashadjustersystem

NOTE:Parkingthevehicleonagradeforalongtimemaydecreaseoilinthelashadjuster,causingairtoenterthehighpressurechamberwhenstartingtheengine.

NOTE:Afterparkingformanyhours,oilmayrunoutfromtheoilpassageandtaketimebeforeoilissuppliedtothelashadjuster,causingairtoenterthehighpressurechamber.

NOTE:Intheabovecases,abnormalnoisecanbeeliminatedbybleedingthelashadjustersystem.

1.

Checkengineoilandaddorchangeoilifrequired.

NOTE:Iftheengineoillevelislow,airissuckedfromtheoilscreen,causingairtoentertheoilpassage.

NOTE:Iftheengineoillevelishigherthanspecification,oilmaybestirredbythecrankshaft,causingoiltobemixedwithalargequantityofair.

NOTE:Ifoilisdeteriorated,airisnoteasilyseparatedfromoil,increasingthequantityofaircontainedinoil.

NOTE:Ifairmixedwithoilentersthehighpressurechamberinsidethelashadjusterfromtheabovecauses,airinthehighpressurechamberiscompressedexcessivelywhilethevalveisopened,resultinginanabnormalnoisewhenthevalvecloses.Thisisthesamephenomenonasthatobservedwhenthevalveclearancehasbecomeexcessive.Thelashadjustercanresumenormalfunctionwhenairenteredthelashadjusterisremoved.

Idletheengineforonetothreeminutestowarmitup.

2.

TSBRevision

HIGH-PRESSURECHAMBER

AKX00329AB

GOOD

MAXIMUMMINIMUM

AKX00328AB

11A-14

ENGINEMECHANICAL

ON-VEHICLESERVICE

3.

Repeattheoperationpattern,showninleftfigure,atnoloadtocheckforabnormalnoise.(Usuallytheabnormalnoiseiseliminatedafterrepetitionoftheoperation10to30times.If,however,nochangeisobservedinthelevelofabnormalnoiseafterrepeatingtheoperationmorethan30times,suspectthattheabnormalnoiseisduetosomeotherfactors.)

Aftereliminationofabnormalnoise,repeattheoperationshowninleftfigurefivemoretimes.

Runtheengineatidleforonetothreeminutestomakesurethattheabnormalnoisehasbeeneliminated.

4.

5.

TSBRevision

AIRBLEEDINGOPERATIONPATTERNOPENTHROTTLE CLOSE

VALVEGRADUALLY THROTTLEVALVE

APPROXI-MATELY

3,000r/min

IDLING 15s 15sOPERATION

ONCE

AKX00330AB

11A-15

ENGINEMECHANICAL

ENGINEASSEMBLY

ENGINEASSEMBLY

REMOVALANDINSTALLATION

M1112001000968

*:Indicatespartswhichshouldbeinitiallytightened,andthenfullytightenedafterplacingthevehiclehorizontalandloadingthefullweightoftheengineonthevehiclebody.

REMOVALSTEPS(Continued)MANIFOLDABSOLUTEPRESSURESENSORCONNECTOR

NOISECONDENSERCONNECTOR

REMOVALSTEPS

THROTTLEPOSITIONSENSORCONNECTOR

EGRCONNECTOR

RIGHTBANKHEATEDOXYGENSENSORCONNECTOR

4.

1.

2.

3.

5.

TSBRevision

19 2 3 4

5

9.0±2.0N·m80±17in-lb

186

1017 7

1 8

16

9.0±2.0N·m

15 80±17in-lb

14 12 9

13

11

AC204398AB

Pre-removalOperation

SkidPlateandUnderCoverRemoval

EngineOilDraining(RefertoGROUP12,On-vehicleSer-viceEngineOilReplacementP.12-3.)

EngineCoolantDraining(RefertoGROUP14,On-vehicleServiceEngineCoolantReplacementP.14-6.)

FuelLinePressureReduction[RefertoGROUP13A,On-vehicleServiceFuelPumpRelayDisconnection(HowtoReducePressurizedFuelLines)P.13A-998.]

HoodRemoval(RefertoGROUP42,HoodP.42-5.)

BatteryRemoval

AirCleanerandAirIntakeHoseRemoval(RefertoGROUP15,AirCleanerP.15-6.)

RadiatorRemoval(RefertoGROUP14,RadiatorP.14-8.)

CoolingFanandClutchAssemblyRemoval(RefertoGROUP14,CoolingFanP.14-10)

FrontExhaustPipeRemoval(RefertoGROUP15,ExhaustPipeandMainMufflerP.15-13.)

TransmissionAssemblyRemoval(RefertoGROUP23A,TransmissionandTransferAssemblyP.23A-563.)

Post-installationOperation

TransmissionAssemblyInstallation(RefertoGROUP23A,TransmissionandTransferAssemblyP.23A-563.)

FrontExhaustPipeInstallation(RefertoGROUP15P.15-13.)

RadiatorInstallation(RefertoGROUP14P.14-8.)

CoolingFanandClutchAssemblyInstallation(RefertoGROUP14,CoolingFanP.14-10)

AirCleanerandAirIntakeHoseInstallation(RefertoGROUP15P.15-6.)

BatteryInstallation

HoodInstallation(RefertoGROUP42,HoodP.42-5.)

EngineOilRefilling(RefertoGROUP12,On-vehicleSer-viceEngineOilReplacementP.12-3.)

EngineCoolantRefilling(RefertoGROUP14,On-vehicleServiceEngineCoolantReplacementP.14-6.)

FuelLeakCheck

SkidPlateandUnderCoverInstallation

CAUTION

11A-16

ENGINEMECHANICAL

ENGINEASSEMBLY

REMOVALSTEPS(Continued)CONTROLWIRINGHARNESSANDCAMSHAFTPOSITIONSENSORWIRINGHARNESSCONNECTOR

KNOCKSENSORCONNECTORIGNITIONCOILCONNECTORLEFTBANKHEATEDOXYGENSENSORCONNECTORCONTROLWIRINGHARNESSANDINJECTIONWIRINGHARNESSCOMBINATIONCONNECTOR

POWERSTEERINGPUMPSWITCHCONNECTOR

A/CCOMPRESSORASSEMBLYCONNECTOR

INTAKEMANIFOLDTUNINGSOLENOIDCONNECTORCRANKSHAFTPOSITIONSENSORCONNECTORENGINECOOLANTTEMPERATUREGAUGEUNITCONNECTOR

ENGINECOOLANTTEMPERATUREGAUGESENSORCONNECTORGROUNDCABLEGROUNDCABLEGROUNDCABLE

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

TSBRevision

11A-17

ENGINEMECHANICAL

ENGINEASSEMBLY

<<A>>

POWERSTEERINGOILPUMPASSEMBLY

A/CCOMPRESSORASSEMBLY

EYEBOLTS

GASKET

HEATPROTECTOR

ENGINEFRONTMOUNTINSULATOR

>>A<<32.ENGINEASSEMBLY

PURGEHOSECONNECTION

HEATERHOSECONNECTION

HEATERHOSECONNECTION

FUELRETURNHOSECONNECTION

FUELHIGH-PRESSUREHOSECONNECTION

O-RING

<<A>>

<<B>>

RequiredSpecialTool:

MB991683:SlingChainSet

REMOVALSERVICEPOINTS

<<A>>POWERSTEERINGOILPUMPASSEMBLY/A/CCOMPRESSORASSEMBLYREMOVAL

RemovetheoilpumpandA/Ccompressor(withthehoseattached).

Suspendtheremovedoilpump(byusingwireorsimilarmaterial)ataplacewherenodamagewillbecausedduringremoval/installationoftheengineassembly.

TSBRevision

20 22

21

5.0±1.0N·m 32

44±9in-lb

29N

25N

24 23

48±7N·m 22±4N·m

36±5ft-lb 16±3ft-lb

26

28 27

N29

30

12±2N·m

102±22in-lb 22±4N·m

16±3ft-lb

31 44±9N·m*33±6ft-lb*

31

AC204056AB

26±4N·m*

19±3ft-lb*

11A-18

ENGINEMECHANICAL

CAMSHAFTANDVALVESTEMSEAL

<<B>>ENGINEASSEMBLYREMOVAL

Checkthatallcables,hoses,harnessconnectors,etc.aredisconnectedfromtheengine.

UsespecialtoolMB991683andchainblocktolifttheengineassemblyslowlyandremoveit.

INSTALLATIONSERVICEPOINT

>>A<<ENGINEASSEMBLYINSTALLATION

Installtheengineassembly.Whendoingso,checkcarefullythatallpipesandhosesareconnected,andthatnonearetwisted,damaged,etc.

CAMSHAFTANDVALVESTEMSEAL

REMOVALANDINSTALLATION

M1112006600352

*Removeandassemblethemarkedpartsineachcylinderunit.

CAMSHAFTREMOVALSTEPS

(Continued)

ROCKERARM,SHAFTANDLASHADJUSTERASSEMBLY(INTAKESIDE)

CAMSHAFTREMOVALSTEPS

<<B>>

>>E<<

2.

CYLINDERHEADASSEMBLY(REFERTOP.11A-32.)CAMSHAFTSPROCKET

<<A>>>>F<<

1.

TSBRevision

31±3N·m

23±2ft-lb

14±1N·m

120±13in-lb

2 4

8*

9* 3 5

10* 6 22±4N·m

16±3ft-lb

11* 7

8*

88±10N·m 9*

65±7ft-lb

11*N 10*

1

AC204227AB

N

7

CAMSECTIONANDJOURNALSECTION

CYLINDER 5

HEAD 4

ENGINEOIL

CAUTION

11A-19

ENGINEMECHANICAL

CAMSHAFTANDVALVESTEMSEAL

CAMSHAFTREMOVALSTEPS

(Continued)

<<B>>

>>E<<

3.

ROCKERARM,SHAFTANDLASHADJUSTERASSEMBLY(EXHAUSTSIDE)

CAMSHAFTPOSITIONSENSORSUPPORT

O-RING

SENSINGCAMSHAFTPOSITIONCYLINDERCAMSHAFT

VALVESTEMSEALREMOVALSTEPS

ROCKERCOVER(REFERTOP.11A-32.)

ROCKERARM,SHAFTAND

LASHADJUSTERASSEMBLY(INTAKESIDE)

ROCKERARM,SHAFTANDLASHADJUSTERASSEMBLY(EXHAUSTSIDE)

VALVESPRINGRETAINERLOCKS

VALVESPRINGRETAINERSVALVESPRINGS

VALVESTEMSEALS

>>D<<

4.

5.

6.

7.

<<B>>

>>E<<

2.

<<B>>

>>E<<

3.

<<C>>

>>C<<

8.

9.

10.

11.

>>B<<

>>A<<

RequiredSpecialTools:

MB990767:EndYokeHolderMD998443:Auto-lashAdjusterHolderMD998715:CrankshaftPulleyHolderPin

MD998772:ValveSpringCompressorMD998774:ValveStemSealInstaller

REMOVALSERVICEPOINTS

<<A>>CAMSHAFTSPROCKETREMOVAL

UsespecialtoolsMD998715andMB990767toremovethecamshaftsprocket.

TSBRevision

MB990767

MD998715

ACX00301AB

11A-20

ENGINEMECHANICAL

CAMSHAFTANDVALVESTEMSEAL

<<B>>ROCKERARMANDSHAFTASSEMBLYREMOVAL

1.InstallspecialtoolMD998443asshownintheillustrationsothatthelashadjusterswillnotfallout.

Neverdisassembletherockerarmandshaftassembly.

2.Loosentherockerarmandshaftassemblymountingbolt,andthenremovetherockerarmandshaftassemblywiththeboltstillattached.

<<C>>VALVESPRINGRETAINERLOCKSREMOVAL

Whenremovingvalvespringretainerlocks,leavethepis-tonofeachcylinderintheTDC(TopDeadCenter)position.ThevalvemayfallintothecylinderifthepistonisnotproperlyintheT