Cylinder Head Assembly: Service and Repair
CYLINDER HEAD GASKETREMOVAL AND INSTALLATION
Pre-removal & Post-installation Operation:
Removal Steps 1-17:
Removal Steps 18-30:
Required Special Tools:
^ MB991454: Engine Hanger Balancer
^ MB991895: Engine Hanger
^ MB991928: Engine Hanger
REMOVAL SERVICE POINTS
[A] RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp as shown to install them in the original position. Then, remove them.
[B] FUEL HIGH-PRESSURE HOSE DISCONNECTION
1. Follow the steps below to unlock the fuel high-pressure hose connector.
1) Insert a flat-tipped screwdriver [6 mm (0.24 inch) wide and 1 mm (0.04 inch) thick] into the retainer of the fuel high-pressure hose connector.
CAUTION:
When pushing up the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
2) Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees to push up the retainer and unlock the fuel high-pressure hose connector.
2. Remove the fuel high-pressure hose.
[C] FRONT CAMSHAFT BEARING CAP ASSEMBLY REMOVAL
1. Temporarily install the engine oil pan which was removed at the valve 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 MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve timing chain was removed.
CAUTION:
Be careful not to drop the camshaft bearing.
4. 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.
[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 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.
[E] CYLINDER HEAD BOLT/CYLINDER HEAD BOLT WASHER/CYLINDER HEAD BOLT AND WASHER 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, 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 or equivalent
3. Install the cylinder head gasket to the cylinder block.
NOTE:
^ Install the cylinder head gasket immediately after applying sealant.
^ 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 1217G or equivalent
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. Within three minutes after the sealant application, install the cylinder head assembly.
[B] CYLINDER HEAD BOLT AND WASHER ASSEMBLY/CYLINDER HEAD BOLT WASHER/CYLINDER HEAD BOLT INSTALLATION
1. Replace the cylinder head bolt and washer with 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 thread of the bolts and to 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:
^ When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
^ When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.
2) Apply paint marks to the head of cylinder head bolt and the cylinder head.
3) Tighten the cylinder head to 90 degrees angle in the tightening order. Additionally tighten to 90 degrees angle, and check that the paint mark on the cylinder head bolt is aligned 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 heads.
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 bolt 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 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 (23 ± 1 ft-lb)
3. Install special tool MB991928 or MB991895 which was installed for supporting the engine and transaxle assembly when the valve 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] 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.
[G] FUEL HIGH-PRESSURE HOSE CONNECTION
CAUTION:
^ When pushing in the retainer of the fuel high-pressure hose connector, pay attention to avoid damage to the retainer.
^ After the installation of the fuel high-pressure hose, slightly pull the fuel high-pressure hose to check that it is connected securely. At this time, also check that there is approximately 1 mm (0.04inch) play.
1. Securely insert the fuel rail stopper into the fuel high-pressure hose connector groove to install the fuel high-pressure hose to the fuel rail.
2. Push in the retainer of the fuel high-pressure hose connector to lock the fuel high-pressure hose and fuel rail.
[H] RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION
1. Insert radiator hose as far as the projection of the water inlet fitting or water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.