Cylinder Head Gasket: Service and Repair
CYLINDER HEAD GASKETREMOVAL AND INSTALLATION
Pre-Removal & Post Installation Operation:
Removal Steps 1-14:
Removal Steps 15-27:
Required Special Tools:
^ MB991454: Engine Hanger Balancer
^ MB991895: Engine Hanger
^ MB991928: Engine Hanger
REMOVAL SERVICE POINTS
[[A]] RADIATOR UPPER HOSE/RADIATOR LOWER HOSE REMOVAL
Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.
[[B]] 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.
[[C]] FRONT CAMSHAFT BEARING CAP REMOVAL
1. Temporarily install the engine oil pan which was removed at the timing chain removal.
CAUTION
When supporting the engine and transaxle assembly with a garage jack, be careful not to deform the engine oil pan.
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 MB991454, MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the timing chain was removed.
CAUTION
Be careful not to drop the camshaft bearing.
4. Loosen the front camshaft bearing cap mounting bolts in the order of number shown in the figure, and remove the front camshaft bearing cap.
[[D]] 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 camshaft bearing cap mounting bolts in the order of number shown in the figure in four or five steps, and remove the camshaft bearing caps.
[[E]] CYLINDER HEAD BOLT/CYLINDER HEAD BOLT ASSEMBLY REMOVAL
Loosen and remove the cylinder head 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. Remove the sealant and grease on the top surface of cylinder block and on the bottom surface of the cylinder head. Then, use the white gasoline or the like to degrease the sealant application surface.
2. Apply the sealant to the top surface of cylinder block as shown in the figure.
Specified sealant: Three bond 1217G
3. Install the cylinder head gasket to the cylinder block.
NOTE: When the cylinder head gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.
NOTE: Install the cylinder head gasket immediately after applying sealant.
4. Apply the sealant to the top surface of cylinder head gasket as shown in the figure.
Specified sealant: Three bond 1217G
CAUTION
After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.
5. Install the cylinder head assembly to the cylinder block.
NOTE: Install the cylinder head assembly immediately after applying sealant.
]]B[[ CYLINDER HEAD BOLT ASSEMBLY/CYLINDER HEAD BOLT INSTALLATION
1. Replace cylinder head bolts with a new ones.
2. For two cylinder head bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the cylinder head bolts.
3. Apply a small amount of engine oil to the cylinder head bolt threads and the washers.
4. Tighten the cylinder head bolts by the following procedure (plastic region angular tightening method.)
1) Tighten the cylinder head bolts to the specified torque in the order of number shown in the figure.
Tightening torque: 35 ± 2 Nm (26 ± 1 ft-lb)
CAUTION
^ The cylinder head bolt is not tightened sufficiently if the tightening angle is less than a 180 degree angle.
^ If the tightening angle exceeds the standard specification, remove the cylinder head 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 degree angle in the order of number 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.
]]C[[ CAMSHAFT BEARING/CAMSHAFT AND CAMSHAFT SPROCKET ASSEMBLY INSTALLATION
CAUTION
^ Be careful not to drop the camshaft bearing.
^ 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.
When replacing the camshaft bearing, according to the identification mark of front camshaft bearing cap in the table below, select a camshaft bearing with the corresponding size. Note that the identification mark of camshaft bearing is stamped on the place shown in the figure.
]]D[[ THRUST CAMSHAFT BEARING CAP/CAMSHAFT BEARING CAP/OIL FEEDING CAMSHAFT BEARING CAP INSTALLATION
1. Install the camshaft bearing caps to the cylinder head.
NOTE: Because the thrust camshaft bearing cap and camshaft 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 bolts to the specified torque in the order of number shown in the figure in two or three steps.
Tightening torque: 12 ± 1 Nm (107 ± 8 in-lb)
]]E[[ FRONT CAMSHAFT BEARING CAP 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 mounting bolts 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 mounting bolts again to the specified torque in the order of the figure (2.)
Tightening torque: 30 ± 2 Nm (23 ± 1 ft-lb)
3. Install special tool MB991454, MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the timing chain was removed.
4. Remove the garage jack which supports the engine and transaxle assembly.
5. Remove the engine oil pan installed temporarily.
]]F[[ FUEL HIGH-PRESSURE HOSE INSTALLATION
CAUTION
After connecting the fuel high-pressure hose, slightly pull it in the pull-out 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.
]]G[[ O-RING INSTALLATION
CAUTION
Avoid adhesion of engine oil or grease to the O-ring.
Fit the O-ring in the water pump inlet pipe groove, wet the O-ring circumference or the pipe mounting area inner wall, and then insert the O-ring.
]]H[[ RADIATOR LOWER HOSE/RADIATOR UPPER HOSE INSTALLATION
1. Insert radiator hose as far as the projection of the water inlet fitting, water outlet fitting or radiator.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.