CYLINDER HEAD GASKET REPLACEMENT [MZR 2.0 DISI i-stop]

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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 [MZR 2.0 DISI i-stop].)

1.  Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2.  Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 2.0 DISI i-stop].)

4.  Disconnect the upper radiator hose. (See RADIATOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

5.  Disconnect the water hose. (See THERMOSTAT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

6.  Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION.)

7.  Remove the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

8.  Disconnect the wiring harness.

9.  Remove in the order indicated in the table.

10.  Install in the reverse order of removal.

11.  Bleed the air from the cooling system. (See ENGINE COOLANT REPLACEMENT [MZR 2.0 DISI i-stop].)

12.  Inspect the compression. (See COMPRESSION INSPECTION [MZR 2.0 DISI i-stop].)

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

Camshaft Removal Note

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

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Note

•  The camshaft caps are to be kept ordered for correct reassembly in their original positions.

Cylinder Head Removal Note

1.  Loosen the cylinder head installation bolts in two to three passes in the order shown in the figure and remove them.

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Cylinder Head Gasket Installation Note

1.  Apply silicone sealant to the areas shown in the figure.

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Caution

•  Install the cylinder head gasket and cylinder head before the applied silicone sealant starts to harden.

2.  Install a new cylinder head gasket to the cylinder block.

3.  Apply silicone sealant to the areas shown in the figure.

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4.  Install the cylinder head referring to the Cylinder Head Installation Note.

Cylinder Head Installation Note

1.  Measure the length of each cylinder head bolt.

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•  Replace any cylinder head bolts that exceed the maximum length.

2.  Tighten the cylinder head bolts in the order shown in the following 5 steps using the SST (49 D032 316).

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Camshaft Installation Note

1.  Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.

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2.  Install the camshaft with No.1 cylinder cam aligned at TDC of compression stroke.

3.  Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure. However, do not apply it to the end journal of the intake camshaft.

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4.  Carefully apply sealant agent (Loctite 518 or 962) to the area indicated in the figure so that it does not leak into the sliding part then, apply the gear oil (SAE No. 90 or equivalent) to the journal.

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Note

•  To prevent engine oil leakage, apply sealant to the rear camshaft cap on the intake side and seal the journal.

5.  Install the camshaft caps and temporarily tighten the camshaft cap bolts evenly in two or three passes, and then tighten the camshaft cap bolts using the following two steps, in the order shown in the figure.

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