Installation

1. Place the head gasket (41) on top of the cylinder block so that the identification mark is facing upwards as shown.

CAUTION: Make sure the identification mark is showing or you will block the oil passages in the engine.






2. Check the shank length of each head bolt. If the "A" limit exceeds 99.4mm (3.913 in.) replaced that bolt.
3. Apply engine oil to the threaded part of the bolt and the washer, tighten bolts as shown.












4. Always torque to exactly 90° where instructed, if you torque less than 90° the bolt will loosen. If you exceed 90° remove the bolt and begin the entire procedure again from step 2.
5. Install valve cover gasket, self-locking nuts and valve cover. Torque valve cover bolts to 3 - 3.5 Nm (2.2 - 2.5 ft.lbs).






6. Make sure timing marks are aligned and, using SSTs (MB990767 and MD998719) or equivalent, install cam sprocket, torque to 88Nm (65 ft.lbs).









7. Remove the cord applied during removal and make sure the timing marks line up as shown.
8. Install upper timing belt cover and the crank position sensor connector bracket.






9. Loosen the water inlet pipe bolt as shown in the image.






10. Apply sealant, part No. MD970389 or equivalent, to the thermostat case assembly as shown in the image above.
11. Install the upper and lower radiator hoses.
12. Install the spark plug cables and PCV hose.
13. Reconnect the accelerator cable connection and the fuel return hose connection.
14. Install a new O-ring and reconnect the high pressure fuel hose connection to the fuel rail.
15. Reconnect the throttle body to water inlet pipe water hose connection.
16. Reconnect the cylinder head to heater unit hose connection.
17. Reconnect the cylinder head to throttle body water hose connection.
18. Reconnect the brake booster vacuum hose connection.
19. Reinstall the air intake hose and breather hose.
20. Reconnect the control harness, A/C compressor, the crank position sensor, the evaporative emission purge solenoid and the fuel injector connectors.Reconnect the EGR temperature sensor, heated oxygen sensor, IAC, and TPS connectors.
21. Reconnect the MDP sensor, capacitor and distributor connectors.
22. Reconnect the A/C engine coolant temperature switch, oxygen sensor, engine coolant temperature sensor and engine coolant temperature gauge unit connectors.
23. Reconnect the vacuum hose connectors.
24. Replace engine oil filter and fill engine oil to capacity.
25. Fill cooling system to capacity with 50-50 mix of water and ethylene glycol based coolant.
26. Reconnect negative battery cable.
27. Start engine. Check and adjust timing as necessary.