CYLINDER HEAD GASKET REPLACEMENT [MZR 1.6]

id0110f6800700

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 [MZR 1.6].)

1.  Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].)

2.  Remove the front wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

3.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Remove the front splash shield No.1 (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

5.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.6].)

6.  Set aside the exhaust manifold to the vehicle rear. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.6].)

7.  Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.6].)

8.  Set the wiring harness aside.

9.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [MZR 1.6].)

10.  Set the cooler pipe and the cooler hose aside. (With A/C) (See REFRIGERANT LINE REMOVAL/INSTALLATION [MZR 1.6].)

11.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 1.6].)

12.  Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [MZR 1.6].)

13.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR 1.6].)

14.  Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION [MZR 1.6].)

15.  Disconnect the fuel hose from the engine side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.6].)

16.  Disconnect the heater hose and radiator hose.

17.  Remove the timing chain and chain guide. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.6].)

18.  Remove in the order indicated in the table.

19.  Install in the reverse order of removal.

20.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.6].)

21.  Start the engine, and inspect and adjust the following:

•  Leakage of engine oil, engine coolant.
•  Runout and contact of pulley and belt.
•  Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZR 1.6].)
•  Compression pressure (See COMPRESSION INSPECTION [MZR 1.6].)

am3zzw00006240

1
Camshaft cap
(See Camshaft Cap Removal Note.)
(See Camshaft Cap Installation Note.)
2
Camshaft
3
Cylinder head
(See Cylinder Head Removal Note.)
(See Cylinder Head Installation Note.)
4
Cylinder head gasket


Camshaft Cap Removal Note

1.  Loosen the camshaft cap installation bolts in two or three steps in the order shown in the figure, and remove them.

am3zzw00013907


Cylinder Head Removal Note

1.  Loosen the cylinder head installation bolts in two or three steps in the order shown in the figure, and remove them.

am3zzw00006242


Cylinder Head Installation Note

1.  Measure the length of each cylinder head installation bolt.

•  If it exceeds the maximum specification, replace the cylinder head installation bolt.
am2zzw00001765
Cylinder head bolt length
Standard: 128.9—129.5 mm {5.075—5.098 in}
Maximum: 130.2 mm {5.125 in}

2.  Tighten the cylinder head installation bolts in three steps in the order shown in the figure.

am3zzw00013908

Step 1: 18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}
Step 2: 85—95°
Step 3: 85—95°


Camshaft Cap Installation Note

1.  Align the No.1 cylinder camshaft position to the TDC position, and install the camshaft.

2.  Install the camshaft caps to the position of a carved seal number to shown in the figure, and tighten the camshaft installation bolts in two or three steps uniformly in the order shown in the figure.

am3zzw00013909

Tightening torque
12—14 N·m {123—142 kgf·cm, 107—123 in·lbf}