Cylinder Head Gasket: Service and Repair
CYLINDER HEAD GASKETREMOVAL AND INSTALLATION
Pre-removal & Post-installation Operation:
Removal Steps 1-13:
Removal Steps 14-26:
Required Special Tools:
^ MB991454: Engine Hanger Balancer
^ MB991527: Hanger
^ MB991895: Engine Hanger
^ MB991928: Engine Hanger
^ MB991956: Engine Hanger Plate
REMOVAL SERVICE POINTS
[[A]] FUEL HIGH-PRESSURE HOSE REMOVAL
1. Remove the stopper of the fuel high-pressure hose.
2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.
NOTE: If the retainer is released, install it securely after removing the fuel high-pressure hose.
[[B]] FRONT CAMSHAFT BEARING CAP ASSEMBLY REMOVAL
CAUTION
Be careful not to drop the camshaft bearing.
Loosen the mounting bolts of front camshaft bearing cap in the order of number shown in the figure, and remove the front camshaft bearing cap assembly.
[[C]] OIL FEEDING CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/THRUST CAMSHAFT BEARING CAP REMOVAL
CAUTION
When the camshaft bearing cap mounting bolts are loosened at once, the mounting bolts jump out by the spring force and the threads are damaged. Always loosen the mounting bolts in four or five steps.
Loosen the mounting bolts of the camshaft bearing caps in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.
[[D]] CYLINDER HEAD BOLT/CYLINDER HEAD BOLT ASSEMBLY REMOVAL
1. Temporarily install the engine oil pan which was removed at the valve timing chain removal.
2. Place a garage jack against the engine oil pan with a piece of wood in between to support the engine and transaxle assembly.
3. Remove special tool MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve timing chain was removed.
4. Loosen and remove the bolts in two or three steps in the order of number shown in the figure.
INSTALLATION SERVICE POINTS
]]A[[ CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION
CAUTION
Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
1. Wipe off the sealant and grease on the top surface of cylinder head block and the bottom surface of the cylinder head, and degrease the surface where the sealant is applied.
2. Apply the sealant to the top surface of cylinder block as shown in the figure.
Specified sealant: Three bond 1227D or equivalent
3. Install the cylinder head gasket to the cylinder block.
NOTE: When the cylinder gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.
4. Apply the sealant to the top surface of cylinder head gasket as shown in the figure.
Specified sealant: Three bond 1227D or equivalent
5. Install the cylinder head assembly.
]]B[[ CYLINDER HEAD BOLT ASSEMBLY/CYLINDER HEAD BOLT INSTALLATION
1. Replace cylinder head bolts with a new ones.
2. For two bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the bolts.
3. Apply a small amount of engine oil to the cylinder head bolt threads and the washers.
4. Tighten the bolts by the following procedure (plastic region angular tightening method).
1) Tighten the bolts to 35 ± 2 Nm (26 ± 1 ft-lb) in the order of number shown in the figure.
CAUTION
^ The bolt is not tightened sufficiently if the tightening angle is less than a 180 degrees angle.
^ If the tightening angle exceeds the standard specification, remove the bolt and repeat the installation steps from Step 1.
2) Put a paint mark on the cylinder head bolt head and cylinder head, tighten to 180±2 degrees in the order shown in the figure, and check that the paint mark on the cylinder head bolt head aligns with the paint mark on the cylinder head.
5. Install special tool MB991928 or MB991895 which was installed for supporting the engine and transmission assembly when the valve timing chain was removed.
6. Remove the garage jack which supports the engine and transaxle assembly.
7. Remove the engine oil pan installed temporarily.
]]C[[ CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY INSTALLATION
CAUTION
When installing the camshaft and camshaft sprocket assembly (exhaust side), be careful not to let the camshaft bearing which is installed to the front cam bearing deviate from its position.
]]D[[ THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP INSTALLATION
1. Install the camshaft bearing caps to the cylinder heads.
NOTE: Because the thrust camshaft bearing cap and cam shaft bearing cap are the same in shape, check the bearing cap number and additionally its symbol to identify the intake and exhaust sides for correct installation.
2. Tighten each camshaft bearing cap mounting bolt to the specified torque in the order of number shown in the figure in two or three steps.
Tightening torque: 12 ± 1 Nm (106 ± 9 in-lb)
]]E[[ FRONT CAMSHAFT BEARING CAP ASSEMBLY INSTALLATION
CAUTION
When the mounting bolts are tightened with the front camshaft bearing cap tilted, the front camshaft bearing cap is damaged. Install the front camshaft bearing cap properly to the cylinder head and camshaft.
1. Install the front camshaft bearing cap to the cylinder head, and temporarily tighten the front camshaft bearing cap to the specified torque in the order of the figure (1).
Tightening torque: 17 ± 3 Nm (13 ± 2 ft-lb)
2. Tighten the front camshaft bearing cap again to the specified torque in the order of the figure (2).
Tightening torque: 30 ± 2 Nm (22 ± 1 ft-lb)
]]F[[ FUEL HIGH-PRESSURE HOSE INSTALLATION
CAUTION
After connecting the fuel high-pressure hose, slightly pull it in the pullout direction to check that it is installed firmly. In addition, check that there is approximately 3 mm (0.12 inch) play. After the check, install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.