626 1999-2001

Cylinder Head

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Removal & Installation



2.0L (Fs) Engine

Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Power steering pump with the lines attached and set aside, if necessary on Protégé models
     
    Accelerator cable
     
    Fuel hose
     
    Ignition coil
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     
    Camshaft
     
    Intake manifold bracket
     

  10.  
  11. Temporarily install the Number 3 engine mount to support the engine, on 626 models.

    Cylinder head bolts by loosening them, in 2-3 steps, in the sequence illustrated
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.0L (FS) engines

     

  12.  

To install:

Click image to see an enlarged view

Fig. Replace any bolts that exceed the maximum length of 4.154 inch (105.5mm)-2.0L (FS)engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.0L (FS) engines

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  2.  
  3. Apply clean engine oil to the bolt threads and seating faces.
  4.  
  5. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 13-16 ft. lbs. (17-22 Nm). If reusing old bolts, which is not recommended, ; make sure the maximum length of the bolt is 4.154 inch (105.5mm). The standard length of the bolt should be 4.103-4.125 inch (104.2-104.8mm).
  6.  
  7. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees.
  8.  
  9. Support the engine assembly with a suitable lifting device and remove the number 3 mount.
  10.  
  11. Install or connect the following:

    Intake manifold bracket
     
    Camshafts
     
    Camshaft pulley, make sure the camshaft sprocket pulleys are positioned with the pins facing up. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 37-44 ft. lbs. (50-60 Nm).

    Click image to see an enlarged view

    Fig. Make sure the camshaft sprocket pulleys are positioned with the pins facing up-2.0L (FS) engine

     
    Ignition coil
     
    Fuel hose
     
    Accelerator cable
     
    Power steering pump, if removed
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

2.5L (Kl) Engine

Specific to:

Mazda 626 1999-2002

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Intake manifold
     
    Fuel hose
     
    Cylinder head cover
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     
    Upper radiator hose
     
    Number 3 engine mount bracket
     
    Seal plate
     
    Water outlet
     
    Camshaft
     
    Alternator stay
     

  10.  
  11. Temporarily install the Number 3 engine mount to support the engine.

    Cylinder head bolts by loosening them, in 2-3 steps, in the sequence illustrated
     
    Cylinder head

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-2.5L (KL) engines

     

  12.  

To install:

Click image to see an enlarged view

Fig. Cylinder head gasket positioning-2.5L (KL) engines



Click image to see an enlarged view

Fig. Cylinder head bolt tightening sequence-2.5L (KL) engines

  1. Install or connect the following:

    New cylinder head gasket
     
    Cylinder head
     

  2.  
  3. Apply clean engine oil to the bolt threads and seating faces.
  4.  
  5. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 17-19 ft. lbs. (23-26 Nm). If reusing old bolts, which is not recommended; make sure the maximum length of the bolt is 5.217 inch (132.5mm). The standard length of the bolt should be 5.166-5.188 inch (131.2-131.8mm).
  6.  
  7. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees.
  8.  
  9. Support the engine assembly with a suitable lifting device and remove the number 3 mount.
  10.  
  11. Install or connect the following:

    Alternator stay
     
    Camshaft
     
    Water outlet
     
    Seal plate
     
    Number 3 engine mount bracket
     
    Upper radiator hose
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while tightening the pulley bolt to 90-97 ft. lbs. (123-132 Nm).
     
    Cylinder head cover
     
    Fuel hose
     
    Intake manifold
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

 
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