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 2—3 steps in the order shown in the figure.


Cylinder Head Removal Note

1. Loosen the cylinder head bolts in 2—3 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 2—3 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:

Rear Turn Light Bulb Removal/Installation
4SD 1. Disconnect the negative battery cable.. 2. Remove the following parts: a. Trunk mat. b. Trunk board. c. Trunk end trim. 3. Partially peel back the trunk side trim.. 4. Remove in the order indicated in the table. 1 Connector 2 ...

Customer Assistance (Canada)
Satisfaction Review Process Your complete and permanent satisfaction is of primary concern to Mazda. All Authorized Mazda Dealers have both the knowledge and tools to keep your Mazda in top condition. In our experience, any questions, problems, or complaints regarding the operation of you ...

Rear Crossmember Removal/Installation
CAUTION: Performing the following procedures without first removing the ABS wheel-speed sensor may possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing the following procedures, disconnect the ABS wheel-speed sensor wiring harness connec ...

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