CYLINDER HEAD GASKET REPLACEMENT [MZR 1.5, MZR 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 [MZR 1.5, MZR 1.6].)

1.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 1.5, MZR 1.6].)

2.  Set the exhaust manifold out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

3.  Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

4.  Remove the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

5.  Disconnect the wiring harness.

6.  Remove the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6].)

7.  Disconnect the heater hose and radiator hose.

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 1.5, MZR 1.6].)

11.  Inspect the compression. (See COMPRESSION INSPECTION [MZR 1.5, MZR 1.6].)

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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.

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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.

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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.
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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.

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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.

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