CYLINDER HEAD GASKET REPLACEMENT [MZ-CD 1.6 (Y6)]

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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 (Y6)].)

1. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.6 (Y6)].)

2. Remove the following parts:

(1) Air hose, combined MAF sensor and IAT, sensor and the air cleaner component (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(2) Fuel pump (See FUEL PUMP UNIT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(3) Lower cylinder head cover, camshaft and timing chain component (See TIMING CHAIN REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(4) Catalytic converter (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(5) Exhaust manifold and turbocharger component (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

(6) Generator (See GENERATOR REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

3. Disconnect the coolant reserve tank hose, upper radiator hose, heater hose and ECT sensor electrical connector. (See THERMOSTAT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

4. Remove in the order indicated in the table.

5. Install in the reverse order of removal.

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1

Oil level gauge

2

Oil level gauge pipe

3

Fuel pump bracket

4

Generator bracket

5

Cylinder head (See Cylinder Head Removal Note.) (See Cylinder Head Installation Note.)

6

Cylinder head gasket (See Cylinder Head Gasket Installation Note.)

Cylinder Head Removal Note

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

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Caution

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

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).

• Make sure that the two locating dowels are installed.

Note

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

Number of teeth

Piston protrusion

Gasket thickness

1

0.7760—0.8250 mm {0.03056—0.03248 in}

1.35 mm {0.0531 in}

2

0.6175—0.7250 mm {0.02432—0.02854 in}

1.25 mm {0.0492 in}

3

0.7260—0.7750 mm {0.02859—0.03051 in}

1.30 mm {0.0512 in}

4

0.8260—0.8750 mm {0.03252—0.03444 in}

1.40 mm {0.0551 in}

5

0.8760—0.9830 mm {0.03449—0.03870 in}

1.45 mm {0.0571 in}

Number of teeth	Piston protrusion	Gasket thickness
1	0.7760—0.8250 mm {0.03056—0.03248 in}	1.35 mm {0.0531 in}
2	0.6175—0.7250 mm {0.02432—0.02854 in}	1.25 mm {0.0492 in}
3	0.7260—0.7750 mm {0.02859—0.03051 in}	1.30 mm {0.0512 in}
4	0.8260—0.8750 mm {0.03252—0.03444 in}	1.40 mm {0.0551 in}
5	0.8760—0.9830 mm {0.03449—0.03870 in}	1.45 mm {0.0571 in}

1. Install a new cylinder head gasket.

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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 20 N·m {2.0 kgf·m, 15 ft·lbf}

2. Tightening to 40 N·m {4.1 kgf·m, 30 ft·lbf}

3. Tightening to 220°

1	Oil level gauge
2	Oil level gauge pipe
3	Fuel pump bracket
4	Generator bracket
5	Cylinder head (See Cylinder Head Removal Note.) (See Cylinder Head Installation Note.)
6	Cylinder head gasket (See Cylinder Head Gasket Installation Note.)