REMOVAL AND INSTALLATION


Pre-removal Operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13A - On-vehicle Service, Reduce Pressurized Fuel Lines ).
  • Under Skid Plate and Engine Room Under Cover Front Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Battery Tray Stay Removal (Refer to GROUP 54A - Battery ).
  • Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold ).
  • Inlet Manifold Stay Removal (Refer to GROUP 15 - Inlet manifold ).
  • Rocker Cover Assembly Removal (Refer to ).
  • Camshaft Sprocket Removal (Refer to ).

 Post-installation Operation
  • Camshaft Sprocket Installation (Refer to ).
  • Rocker Cover Assembly Installation (Refer to ).
  • Inlet Manifold Stay Installation (Refer to GROUP 15 - Inlet manifold ).
  • Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold ).
  • Battery Tray Stay Installation (Refer to GROUP 54A - Battery ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Under Skid Plate and Engine Room Under Cover Front Installation (Refer to GROUP 51 - Under Cover ).
  • Fuel Leak Check




Removal steps


·
 Radiator upper hose connection (Refer to GROUP 14 - Radiator ).
<<A>>
 >>C<<
 1.
 Cylinder head bolt

>>B<<
 2.
 Cylinder head assembly

>>B<<
 ·
 O-ring (Refer to GROUP 14 - Water Hose and Water Pipe )

>>A<<
 3.
 Cylinder head gasket

REMOVAL SERVICE POINT

<<A>> CYLINDER HEAD BOLT REMOVAL

Use the special tool Cylinder head bolt wrench (MB991654) to loosen the cylinder head bolts.

INSTALLATION SERVICE POINTS

>>A<< CYLINDER HEAD GASKET INSTALLATION
1.
caution Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.
Degrease the cylinder head gasket mounting surface.

2.Assemble to the cylinder block so the cylinder head gasket identification mark "64-278" is at the top surface and on the inlet side.

>>B<< O-RING/CYLINDER HEAD ASSEMBLY INSTALLATION
1.Insert the O-ring to the water pipe, and coat the outer portion of the O-ring with water or engine coolant.
2.Insert the water pipe to the water by-pass fitting of the cylinder head assembly, and install the cylinder head assembly to the cylinder block.

>>C<< CYLINDER HEAD BOLTS INSTALLATION

1.Check that the nominal length of each cylinder head bolt meets the limit. If it exceeds the limit, replace the bolt with a new one.
Limit (A): 99.4 mm
2.Apply a small amount of engine oil to the thread of the bolts and to the washers.


3.Use special tool cylinder head bolt wrench (MB991654) to tighten the cylinder head bolts as follows:
(1) Tighten the cylinder head bolts to 78 ± 2 N·m in the order shown.
(2) Loosen the bolts fully in the reverse order of that shown.
(3) Tighten the cylinder head bolts to 20 ± 2 N·m in the order shown.
(4) Apply a paint mark to the heads of the cylinder head bolts and cylinder head, then tighten 90 degree angle as shown.
(5)
caution The bolt is not tightened sufficiently if the bolt is tightened less than 90 degree angle.
Tighten the bolt an additional 90 degree angle as shown. Then check to see that the paint mark on the head of the cylinder head bolts and the paint mark on the cylinder head are aligned.
(6) If tightening the bolt 90 degree angle results in moving the paint mark on the bolt past the paint mark on the cylinder head, remove the bolt and start over from step 1.