CYLINDER HEAD GASKET REPLACEMENT [MZR-CD (RF Turbo)]

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-CD (RF Turbo)].)

Caution

• To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the fuel injection pipe.

• To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing and installing the fuel injector.

• The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the service record when removing and installing the fuel injection pipe. If removing it for the sixth time, be sure to replace it with a new one.

1. Remove the timing belt. (See TIMING BELT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION (MZR-CD (RF Turbo)).)

3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (See POWER STEERING OIL PUMP (MZR-CD (RF Turbo)) REMOVAL/INSTALLATION.)

4. Remove the turbocharger. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

5. Remove all the glow plugs. (See GLOW PLUG REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

6. Remove in the order shown in the table.

7. Install in the reverse order of removal.

8. Inspect valve clearance. (See VALVE CLEARANCE INSPECTION [MZR-CD (RF Turbo)].)

9. Inspect the engine oil level.

10. Inspect the compression. (See COMPRESSION INSPECTION [MZR-CD (RF Turbo)].)

11. Start the engine and:

(1) Inspect the pulleys and the drive belt for runout and contact.

(2) Inspect the engine oil, engine coolant, and fuel leakage.

(3) Inspect the idle speed. (See IDLE SPEED INSPECTION [MZR-CD (RF Turbo)].)

Injection Pump Pulley Removal Note

1. Verify that timing marks are correctly aligned.

Caution

• To prevent the bolts (M8 x 1.25) from damaging the injection pump and pulley, do not fully tighten the fixing bolts. If it contacts the pulley surface, it will damage the pulley.

2. Fix the injection pump pulley to the bracket using two bolts (M8 x 1.25).

3. Loosen the injection pump pulley lock nut.

4. Separate the injection pump pulley from the injection pump shaft using the SST.

5. Remove the injection pump pulley fixed bolts (M8 x 1.25).

Drive Gear Removal Note

1. Hold the camshaft using the SST.

2. Remove the drive gear lock bolt.

Camshaft Pulley Removal Note

1. Hold the camshaft using the SST.

2. Remove the camshaft pulley lock bolt.

3. Remove the camshaft pulley using the SST.

Seal Plate Removal Note

1. Remove the seal plate from the engine component. However, the seal plate cannot be removed completely. Separate the seal plate from the engine component by removing the fitting bolts so that the cylinder head can be removed.

Rocker Arm and Rocker Arm Shaft Removal Note

1. Loosen the bolts in two or three steps in the order shown.

Cylinder Head Removal Note

1. Loosen the cylinder head bolts in two or three steps in the order shown.

Cylinder Head Installation Note

1. Before installation, measure the length of each bolt. Replace any that exceed the maximum length.

Standard length

159.7- 160.3 mm {6.288- 6.311 in}

Maximum length

161.0 mm {6.338 in}

2. Tighten the bolts in two or three steps in the order shown.

Tightening torque

29 N·m {3.0 kgf·m, 22 ft·lbf}

3. Put a paint mark on each bolt head.

4. Using the marks as a reference, tighten the bolts by turning each 90°-105° in the sequence shown.

5. Further tighten each bolt by turning another 90°-105°.

6. Then further tighten each bolt by turning another 90°-105°.

Rocker Arm and Rocker Arm Shaft Installation Note

1. Apply sealant as shown in the figure.

Thickness

2 mm {0.079 in}

2. Install the camshaft caps according to the cap number.

3. Install the rocker arm shaft plane side upward.

Caution

• Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust receiving area of the cylinder head journal. To avoid this, the following procedure must be observed.

4. Tighten the bolts in two or three steps in the order shown.

Tightening torque

25-30 N·m {2.5-3.1 kgf·m, 18-22 ft·lbf}

5. Apply clean engine oil to the new oil seal.

6. Push the oil seal slight in by hand.

7. Tap the oil seal into the cylinder head using the SST and a hammer.

Side Wall Installation Note

1. Apply silicone sealant as shown in the figure.

Thickness

2 mm {0.079 in}

Cylinder Head Cover Installation Note

1. Apply silicone sealant to the shaded areas.

Thickness

2 mm {0.079 in}

2. Tighten the bolts in the order shown.

Tightening torque

7.9-10.7 N·m {80-110 kgf·cm, 69.5-95.4 in·lbf}

Seal Plate Installation Note

1. Install the seal plate and hand tighten the bolt in the order A to B.

2. Tighten the bolts in the order shown.

Tightening torque

7.9-10.7 N·m {80-110 kgf·cm, 69.5-95.4 in·lbf}

Camshaft Pulley Installation Note

1. Hold the camshaft using the SST.

Gear Case Installation Note

1. Apply silicone sealant as shown in the figure.

Thickness

1.5-2.5 mm {0.060-0.098 in}

2. Tighten the bolts in clockwise order.

Drive Gear Installation Note

1. Hold the camshaft using the SST.

2. Tighten the drive gear lock bolt.

Gear Cover Installation Note

1. Apply silicone sealant as shown in the figure.

Thickness

1.5-2.5 mm {0.060-0.098 in}

2. Tighten the bolts in clockwise order.

Injection Pump Pulley Installation Note

Caution

• To prevent the bolts (M8 x1.25) from damaging the injection pump and pulley, do not fully tighten the fixing bolts. If it contacts the pulley surface, it will damage the pulley.

1. Fix the injection pump pulley to the bracket using two bolts (M8 x 1.25).

Idler Assembly Note

Caution

• The idler has a front and back relative to the engine, therefore when installing make sure that the longer projection of the shaft is on the engine side as indicated in the figure.