Question: Can you replace the head gasket without removing the engine?

@welz

I’m not an expert, but it’s overhead camshafts so I would guess that it would need to come out to get proper access to the all the associated gubbins on the left side (as you face the engine). Getting the fuel injection rails and stuff off will also be a PITA with the engine in.

 

Ich schätze es wird einfacher wenn du den Motor rausnimmst, aber wenn du genug Platz im Motorraum hast, warum nicht?

I guess it will be easier if you take the engine out, but if you have enough space in the engine compartment, why not?

 

Further thoughts may be to undo the engine mounts and jack up the left hand side to get better access to the ancillary pulleys and timing chain/belt assembly. It would save hassle with the gearbox.

It goes without saying that the bonnet will need to be removed but that’s only a few bolts.

 

It is NOT nessesairy (i've done a replacement with the engine in the car).
However you need some small hands for some of the components like timing chaine tensioner/ intake manifold, and some electronic plugs etc.

So if you would pay for the labour, i would advice to take it out, since it is most likely faster with the correct tools,
if you do it yourself and have plenty of time avaiable, you can do it yourself.

Keep an real eye out for the timing chaine, since you do not want to drop it! (if you do, you cannot see the mark on the bottom timing gear, and than the engine might has to come out).

 

Hi Welz,

You have too unscrew everything that is attached to the upper parts of the motor block,
But also Airco/headlights/pumps/ intake and outlet mannifould/radiator/turbo etc.
You need roughly 5-6 different gaskets, and also some 1 time use parts like the white couplet in the exhaust.
This also means unplugging some hard to reach sensors/bolts. So small hands would be nice

For the timing chaine i took a piece of string and rubber band, and attched it to the open bonnet.

you don't really need special tools (I did it without) but this do meand sometimes carefuly asses which is the best way to do things.
I did need to unscrew my cam shafts since i needed to change a valve, if you only do the main gasket, probably you don't have to do this, this was the most tricky part where i could have used some special tools.

It will take you most likely 2-3 full days if you (just like me) have some experience with tooling around, but never replaced something from an car engine.
And use the Manual from the resources! this is very usefull!

I also had a small bridge with which i could raise the car, very usefull, but if you simply jack it up a bit, it would also work, but sometimes a bit hard for your back

 

Good luck!

let me know if you run into something and need to talk to someone,
I also have some spare parts from a 0.7 copen, including motor parts
In case you break something

 

@Ewoud van Munster

A great addition to the forum as you’re someone that has actually done the work. Sadly, I sold my Copen in the summer but I suspect you may be invited to a lot of Copen meetings so others can use your experience.

Leverkusen anybody ?

 

Hi Rob,

A pity you sold your Copen,
you bought something bigger?
Or you didn't liked all the positive attention it got ?

Yes i will try to join the germany meeting somewhere in june it was, (is on my calander )
I have spoken with my Daihatsu dealer, who has bought most of the parts i needed for revision of the valves/turbo etc,

The fun part was that he said he had never taken such a motor apart.
He explained that Daihatsu makes those engine quite reliable, and maintenance free, so they never has be taken apart.
Unfortunattely that also means that in a small crash or problem like a cilinder gasket leak, the car is most likely not worth the large expeses of labour costs...

 

Hi,

Yes it is officially advised, but the first time i didn't do it.

But don't try to cut too many corners with gaskets etc or you end up doing it all over again!

 

I honestly wouldn t know, bought all my parts at dealer

 

Ewoud,

It was a great car and I spent more than I should have done bringing up to the best condition. Unfortunately, the availability of spares and some minor issues that I couldn’t live with meant I bought an MX5 folding hard top. Other than parts availability, it has a useable boot even when the roof is down.

I’m still very happy that the Copen was my introduction to open top driving even if it took me until almost 60 to get there !

 

Weiz, here is another site Head Bolts for DAIHATSU Copen I 0.7 (L880) (68 HP from 2003 ) they pretty much have the same as the site you linked above, but the more sources the better.