CYLINDER HEAD GASKET REPLACEMENT [MZ-CD 1.6]

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Warning

• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [MZ-CD 1.6].)

1. Disconnect the negative battery cable.

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.6].)

3. Remove the drive belt auto tensioner. (See ENGINE DISASSEMBLY/ASSEMBLY [MZ-CD 1.6].)

4. Remove the windshield wiper arm and blade. (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

5. Remove the cowl grille. (See COWL GRILLE REMOVAL/INSTALLATION.)

6. Remove the cowl panel. (See COWL PANEL REMOVAL/INSTALLATION.)

7. Remove the intake shutter valve, charge air cooler outlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

8. Remove the charge air cooler inlet hose and intake air pipe No.1. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

9. Remove the catalytic converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

10. Remove the intake air pipe No.2. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

11. Remove the generator installation bolt shown in the figure.

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12. Remove the fuel filter component. (See FUEL FILTER REMOVAL/INSTALLATION [MZ-CD 1.6].)

13. Remove the EGR cooler with bypass valve and EGR valve. (See EGR VALVE REMOVAL/INSTALLATION [MZ-CD 1.6].)

14. Remove the thermostat. (See THERMOSTAT REMOVAL/INSTALLATION [MZ-CD 1.6].)

15. Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [MZ-CD 1.6].)

16. Remove the coolant reserve tank with the hose still connected.

17. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [MZ-CD 1.6].)

18. Disconnect the ventilation hose from the cylinder head cover.

19. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION [MZ-CD 1.6].)

20. Remove the HLA. (See HYDRAULIC LASH ADJUSTER (HLA) REMOVAL/INSTALLATION [MZ-CD 1.6].)

21. Remove the Supply pump. (See SUPPLY PUMP REMOVAL/INSTALLATION [MZ-CD 1.6].)

22. Remove the oil inlet pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

23. Disconnect the oil outlet pipe from the oil cooler.

24. Remove in the order indicated in the table.

25. Install in the reverse order of removal.

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1

Dipstick

2

Dipstick pipe

3

Generator bracket

4

O-ring

(See O-ring Removal Note.)

(See O-ring Installation Note.)

5

Lower cylinder head

(See Lower Cylinder Head Removal Note.)

(See Lower Cylinder Head Installation Note.)

6

Cylinder head gasket

(See Cylinder Head Gasket Installation Note

O-ring Removal Note

Note

• Note the position of the components before removal.

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Lower Cylinder Head Removal Note

1. Loosen the cylinder head bolts in 2—3 passes in the order shown in the figure.

Caution

• Do not remove the cylinder head bolts until the cylinder head has cooled to below 30 °C {86 °F}.

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Cylinder Head Gasket Installation Note

Caution

• The thickness of the new cylinder head gasket must be the same as that of the old one (hole/tooth marked).

Note

• There is a choice of five different thickness sizes, depending on the degree of piston protrusion in the engine. The number of notch (one to five) indicates the gasket thickness.

Number of notch

Piston protrusion

Gasket thickness

1

0.684—0.734 mm {0.0270—0.0288 in}

1.35 mm {0.0531 in}

2

0.533—0.634 mm {0.0210—0.0249 in}

1.25 mm {0.0492 in}

3

0.634—0.684 mm {0.0250—0.0269 in}

1.30 mm {0.0512 in}

4

0.734—0.784 mm {0.0289—0.0308 in}

1.40 mm {0.0551 in}

5

0.784—0.886 mm {0.0309—0.0348 in}

1.45 mm {0.0571 in}

Number of notch	Piston protrusion	Gasket thickness
1	0.684—0.734 mm {0.0270—0.0288 in}	1.35 mm {0.0531 in}
2	0.533—0.634 mm {0.0210—0.0249 in}	1.25 mm {0.0492 in}
3	0.634—0.684 mm {0.0250—0.0269 in}	1.30 mm {0.0512 in}
4	0.734—0.784 mm {0.0289—0.0308 in}	1.40 mm {0.0551 in}
5	0.784—0.886 mm {0.0309—0.0348 in}	1.45 mm {0.0571 in}

Lower Cylinder Head Installation Note

1. Tighten the new cylinder head installation bolts using the SST (49 D032 316) in three steps in the order shown in the figure.

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1. Tightening to 10 N·m {102 kgf·cm, 89 in·lbf}

2. Tightening to 20 N·m {2.0 kgf·m, 15 ft·lbf}

3. Tightening to 260°

O-ring Installation Note

Note

• Make sure that the components are installed to the position noted before removal.

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1	Dipstick
2	Dipstick pipe
3	Generator bracket
4	O-ring (See O-ring Removal Note.) (See O-ring Installation Note.)
5	Lower cylinder head (See Lower Cylinder Head Removal Note.) (See Lower Cylinder Head Installation Note.)
6	Cylinder head gasket (See Cylinder Head Gasket Installation Note