Mazda 3 manuals

Mazda 3 Service Manual: Cylinder Head Gasket Replacement [Mzr 2.0, Mzr 2.5]

Mazda 3 Service Manual / Engine / Engine Assembly / Valvetrain, Cylinder Head / Cylinder Head Gasket Replacement [Mzr 2.0, Mzr 2.5]

WARNING:

1. Remove the timing chain..

2. Remove the generator, but do not remove it from the vehicle. Fix the generator using a rope to prevent it from falling. (MZR 2.5).

3. Remove the exhaust manifold..

4. Remove the intake manifold..

5. Drain the engine coolant..

6. Disconnect the upper radiator hose..

7. Disconnect the water hose..

8. Disconnect the heater hose..

9. Disconnect the wiring harness.

10. To firmly support the engine, first set the engine jack to the oil pan.


11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Bleed the air from the cooling system..

14. Inspect the compression..



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

NOTE:

1. Loosen the camshaft cap bolts in 23 steps in the order shown in the figure.


Cylinder Head Removal Note

1. Loosen the cylinder head bolts in 23 steps in the order shown in the figure.


Cylinder Head Gasket Installation Note

1. Apply silicone sealant to the areas shown in the figure.

CAUTION:


2. Install the cylinder block with a new cylinder head gasket.

3. Apply silicone sealant to the areas shown in the figure.


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.


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

.


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.


2. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.

3. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.


4. Temporarily tighten the camshaft cap bolts evenly in 23 steps.

5. Tighten the camshaft cap bolts in the order shown in the following two steps.


Camshaft Position (CMP) Sensor Removal/Installation [Mzr 2.0, Mzr 2.5]
CAUTION: When replacing the CMP sensor, make sure there is no foreign material on it such as metal shavings. If it is installed with foreign material, the sensor output signal will malfu ...

Valve Clearance Adjustment [Mzr 2.0, Mzr 2.5]
1. Remove the battery cover.. 2. Disconnect the negative battery cable. 3. Remove the plug hole plate.. 4. Disconnect the wiring harness. 5. Remove the ignition coils.. 6. Remove the spark p ...

Other materials:

Electric Power Steering Oil Pump Component Removal/Installation
CAUTION: Be careful not to drop the electric power steering oil pump component as the internal parts of the EHPAS CM could be damaged. Replace the electric power steering oil pump component if it is subjected to an impact. 1. Remove the front mudguard (RH).. 2. Remove the aerod ...

Parking Brake
CAUTION Driving with the parking brake on will cause excessive wear of the brake parts. NOTE For parking in snow, refer to Winter Driving regarding parking brake use. Setting the parking brake Depress the brake pedal and then firmly pull the parking brake lever fully upwar ...

Neutral Switch Removal/Installation [G66 M R]
1. Remove the battery cover.. 2. Disconnect the negative battery cable. 3. Remove the battery component. (ex: battery, battery tray and PCM component). 4. Remove the aerodynamic under cover No.2.. 5. Drain the oil from the transaxle.. 6. Remove the neutral switch. 7. Install the neu ...

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