Cylinder Head Gasket: Service and Repair

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS
[[A]] CAMSHAFT SPROCKET REMOVAL

CAUTION: Always turn the crankshaft in the forward direction (clockwise).





1. Turn the crankshaft in the forward direction (clockwise) to align the timing mark so that number 1 cylinder is at TDC on the compression stroke.





2. Secure the camshaft sprocket and the timing belt with tie wraps to prevent slippage between the camshaft sprocket and the timing belt.





3. Use special tools MB990767 and MD998719 to stop the camshaft sprocket from fuming.

CAUTION: Do not turn the crankshaft after the camshaft sprocket is removed.

4. Remove the camshaft sprocket.

[[B]] CYLINDER HEAD BOLTS REMOVAL

CAUTION: Be careful not to damage or deform the plug guides when removing the cylinder head bolts. Plug guides cannot be replaced separately.





Using special tool MB991653, loosen the bolts in two or three steps in the order of the numbers shown in the illustration, then remove the bolts. Remove the cylinder head assembly.

INSTALLATION SERVICE POINTS
]]A[[ CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting surface.
2. Match the shapes of the cylinder head holes with their respective cylinder head gasket holes.

]]B[[ CYLINDER HEAD ASSEMBLY/CYLINDER HEAD BOLTS INSTALLATION





1. Before installing the cylinder head bolts, check if length (A) is within limits. If it is outside the limit, replace the bolts.
Limit (A): 96.4 mm (3.8 inches)
2. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt.

CAUTION:
- Always tighten cylinder head bolts at a 90 degree angle.
- If it is less than 90 degree angle, the bolt will loosen.
- If it is more than 90 degree angle, remove the head bolt and repeat the procedure from step 1.











3. Using special tool MB991653, tighten the bolts by the following procedure.

]]C[[ CAMSHAFT SPROCKET INSTALLATION





Use special tools MD998719 and MB990767 in the same way as during removal to install the camshaft sprocket.

]]D[[ O-RING/HIGH-PRESSURE FUEL HOSE INSTALLATION

CAUTION: Do not allow engine oil to enter the fuel rail.

1. Apply a small amount of new engine oil to the O-ring.





2. While turning the high-pressure fuel hose to the right and left, slide it into the fuel rail. Be careful not to damage the O-ring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably binding. Disconnect the high-pressure fuel hose and check the O-ring for damage.
4. Re-insert the fuel rail and confirm the hose turns smoothly.