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Cylinder Head Gasket Replacement: Notes

WARNING:
  • A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.
  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Highly pressurized fuel may spray out if the fuel line is cut.

    Due to the following dangers occurring with a fuel spray, always complete the "Fuel Line Safety Procedure" to prevent the fuel from spraying.

    • Fuel may cause irritation if it comes in contact with skin and eyes.
    • If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
CAUTION:
  • If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.
  1. Disconnect the negative battery terminal. (Refer to NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. Remove the front under cover No. 1 and No. 2. (Refer to FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .) (Refer to FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  3. Remove the front splash shield. (Refer to FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
  4. Drain the engine oil. (Refer to ENGINE OIL REPLACEMENT .)
  5. Drain the engine coolant. (Refer to ENGINE COOLANT REPLACEMENT .)
  6. Remove the plug hole plate. (Refer to PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  7. Remove the air cleaner, air hose and fresh air duct as a single unit. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  8. Remove the battery and battery tray. (Refer to BATTERY REMOVAL/INSTALLATION .)
  9. Remove the air inlet pipe. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  10. Remove the EGR cooler and EGR valve component. (Refer to EGR COOLER REMOVAL/INSTALLATION .) (Refer to EGR VALVE REMOVAL/INSTALLATION .)
  11. Remove the intake manifold. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  12. Remove the WU-TWC. (Refer to EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  13. Remove the dynamic pressure turbo. (Refer to DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION .)
  14. Remove the exhaust manifold. (Refer to EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  15. Remove the ignition coil/ion sensors. (Refer to IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION .)
  16. Remove the vacuum pump. (Refer to VACUUM PUMP REMOVAL/INSTALLATION .)
  17. Remove the high pressure fuel pump and rear housing. (Refer to HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION .)
  18. Remove the drive belt. (Refer to DRIVE BELT REMOVAL/INSTALLATION .)
  19. Remove the oil pan. (Refer to OIL PAN REMOVAL/INSTALLATION .)
  20. Remove the timing chain and chain guide. (Refer to TIMING CHAIN REMOVAL/INSTALLATION .)
  21. Remove the OCV. (Refer to OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION .)
  22. Disconnect the radiator hoses shown in the figure.
    Fig 1: Identifying Upper Radiator Hose Clips
    G10946539Courtesy of MAZDA MOTORS CORP.
  23. Remove in the order indicated in the table.
  24. Install in the reverse order of removal.
  25. Refill with the specified type and amount of the engine oil. (Refer to ENGINE OIL REPLACEMENT .)
  26. Refill the engine coolant. (Refer to ENGINE COOLANT REPLACEMENT .)
  27. Start the engine, and inspect and adjust the following:
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