CYLINDER HEAD GASKET REPLACEMENT [MZR 2.3 DISI Turbo]

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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 2.3 DISI Turbo].)

1.  Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

2.  Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

3.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

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

5.  Disconnect the upper radiator hose. (See RADIATOR REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

6.  Remove the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 2.3 DISI Turbo].)

7.  Disconnect the connectors and the wiring harnesses related to the cylinder head gasket removal/installation.

8.  Remove in the order indicated in the table.

9.  Install in the reverse order of removal.

10.  Bleed the air from the cooling system. (See ENGINE COOLANT REPLACEMENT [MZR 2.3 DISI Turbo].)

11.  Inspect the compression. (See COMPRESSION INSPECTION [MZR 2.3 DISI Turbo].)

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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 2—3 steps in the order shown in the figure.

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Note
•  The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.


Cylinder Head Removal Note

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

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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.
Thickness
4—7 mm {0.16—0.27 in}

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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Thickness
4—7 mm {0.16—0.27 in}

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.
Cylinder head bolt stem length
Standard: 144.7—145.3 mm {5.697—5.720 in}
Maximum: 146 mm {5.74 in}

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

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Tightening procedure
Step 1: 3—11 N·m {31—112 kgf·cm, 27—97 in·lbf}
Step 2: 13—17 N·m {133—173 kgf·cm, 116—150 in·lbf}
Step 3: 43—47 N·m {4.4—4.7 kgf·m, 32—34 ft·lbf}
Step 4: 88—92°
Step 5: 88—92°


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.  With No.1 cylinder cam aligned at TDC of the compression stroke, install the camshafts.

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 962T) 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.
Sealan agent bead width
0.5—1.5 mm {0.02—0.05 in}

5.  Temporarily tighten the camshaft cap bolts evenly in 2—3 steps.

Note
•  Do not tighten the bolts during this step.

6.  Tighten the camshaft cap bolts in two steps in the order shown in the figure.

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Tightening procedure
Step 1: 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}
Step 2: 14—17 N·m {1.5—1.7 kgf·m, 11—12 ft·lbf}