Cylinder Head Assembly: Service and Repair

CYLINDER HEAD GASKET REPLACEMENT [MZR 1.5]

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". Before Service Precaution

1. Remove the timing chain. Service and Repair

2. Set the exhaust manifold out of the way. Service and Repair

3. Remove the intake manifold. Service and Repair

4. Disconnect the heater hose and radiator hose.

5. Remove in the order indicated in the table.

6. Install in the reverse order of removal.

7. Inspect the compression. Testing and Inspection

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.

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.

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.

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.

- Tightening torque: 18-22 Nm {1.8-2.2 kgf-m, 13-16 ft-lbf}
- Tightening angle: 85°-95°
- Tightening angle: 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.

Tightening torque
- 12-14 Nm {116-145 kgf-cm, 100-125 in-lbf}