Mazda B-Series 1998-06

Rocker Arm (Valve) Cover

Print

Removal & Installation



2.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Disengage the wiring connector from the Intake Air Temperature (IAT) sensor.
  4.  
  5. Remove the air cleaner duct assembly.
  6.  
  7. Remove the accelerator control splash shield.
  8.  
  9. Disconnect the accelerator cable.
  10.  
  11. Disconnect the crankcase vent hose from the valve cover.
  12.  
  13. Unplug the wiring harness connectors from the Idle Air Control (IAC) valve and the Throttle Position Sensor (TPS).
  14.  
  15. Label each spark plug wire prior to its removal in order to ease the installation of the wires on the correct spark plugs. Remove the spark plug wires.
  16.  
  17. Remove the exhaust side spark plug wire retainer from the studs on the valve cover.
  18.  
  19. Remove the throttle body.
  20.  
  21. Remove the vacuum line from the EGR valve and intake.
  22.  
  23. Remove the valve cover mounting bolts.
  24.  
  25. Remove the valve cover. Remove and discard gasket.
  26.  



Click image to see an enlarged view

Fig. Remove the 8 mounting bolts and lift the valve cover off of the engine

To install:

  1. Clean all gasket material from the cylinder heads and rocker arm cover gasket surfaces.
  2.  
  3. Install a new gasket on the valve cover.
  4.  
  5. Install the valve cover and mounting bolts. Tighten the mounting bolts to 80-115 inch lbs. (9-13 Nm).
  6.  
  7. Connect the vacuum line to the EGR valve and intake.
  8.  
  9. Install the throttle body.
  10.  
  11. Install the exhaust side spark plug wire retainer onto the valve cover studs.
  12.  
  13. Connect the spark plug wires.
  14.  
  15. Plug in the wiring harness connectors to the IAC valve and TPS.
  16.  
  17. Connect the crankcase vent hose to the valve cover.
  18.  
  19. Connect the accelerator cable.
  20.  
  21. Install the accelerator control splash shield.
  22.  
  23. Install the air cleaner duct assembly.
  24.  
  25. Attach the wiring connector to the IAT sensor.
  26.  
  27. Connect the negative battery cable. Start the engine and check for oil leaks.
  28.  

3.0L Engine

Failure to install new valve cover gaskets and valve cover reinforcement pieces will result in oil leaks.

  1. Disconnect the negative battery cable.
  2.  
  3. If removing the right valve cover, perform the following steps:
    1. Disconnect the engine control sensor wiring from the ignition coil.
    2.  
    3. Disconnect and label the right side spark plug wires.
    4.  
    5. Disconnect the Intake Air Temperature (IAT) and Mass Air Flow (MAF) sensor wiring harnesses. Position the wiring harnesses aside.
    6.  
    7. Disconnect any vacuum lines.

      Click image to see an enlarged view

      Fig. Loosen the attaching bolts and remove the ignition coil mounting bracket

    8.  
    9. Remove the ignition coil mounting bracket.
    10.  
    11. Disconnect the crankcase ventilation tube.
    12.  

  4.  
  5. If removing the left valve cover, perform the following steps:
    1. Remove the upper intake manifold.
    2.  
    3. Disconnect and label the left side spark plug wires.
    4.  

  6.  
  7. Remove the valve cover mounting fasteners.
  8.  
  9. Remove the valve cover(s). It will probably be necessary to tap the cover loose with a plastic or rubber mallet.
  10.  
  11. Remove the valve cover gasket(s) if necessary.
  12.  

To install:

  1. Clean all gasket material from the cover and head.
  2.  
  3. Before installing the new gasket(s), apply a 0.16-0.23 inch (4-6mm) bead of silicone sealant to the seam between the lower intake manifold and cylinder head.
  4.  
  5. Install the new gasket(s).
  6.  



Click image to see an enlarged view

Fig. Valve cover mounting fastener tightening sequence

  1. Install the valve cover onto the cylinder head in correct position, then install the mounting fasteners. Tighten the mounting fasteners in correct sequence to 8-10 ft. lbs. (10-14 Nm).
  2.  
  3. If installing the left valve cover, perform the following steps:
    1. Connect the left side spark plug wires.
    2.  
    3. Install the upper intake manifold.
    4.  

  4.  
  5. If installing the right valve cover, perform the following steps:
    1. Connect the crankcase ventilation tube.
    2.  
    3. Install the ignition coil mounting bracket.
    4.  
    5. Connect any vacuum lines.
    6.  
    7. Connect the IAT and MAF sensor wiring harnesses.
    8.  
    9. Connect the right side spark plug wires.
    10.  
    11. Connect the engine control sensor wiring to the ignition coil.
    12.  

  6.  
  7. Connect the negative battery cable.
  8.  

4.0L Engine

Failure to install new valve cover gaskets and valve cover reinforcement pieces will result in oil leaks.

  1. Disconnect the negative battery cable.
  2.  
  3. If removing the right valve cover, perform the following steps:
    1. Remove the air cleaner outlet tube.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the upper radiator hose.
    6.  
    7. Disengage the engine control sensor wiring from the Mass Air Flow (MAF) sensor and alternator.
    8.  
    9. Disconnect the heater water hose.
    10.  
    11. Disconnect the cruise control actuator cable.
    12.  
    13. Disconnect the hose from the vacuum reservoir.
    14.  
    15. Disconnect and tag the spark plug wires.
    16.  

  4.  
  5. If removing the left valve cover, perform the following steps:
    1. Remove the upper intake manifold.
    2.  
    3. Disconnect the vacuum lines from the EGR valve.
    4.  
    5. Loosen the mounting bolts and remove the EGR valve.
    6.  
    7. Remove the nut and stud bolt.
    8.  

  6.  
  7. Remove the valve cover mounting bolts and stud bolt.
  8.  
  9. Remove the valve cover(s). It will probably be necessary to tap the cover loose with a plastic or rubber mallet.
  10.  
  11. Remove the valve cover gaskets.
  12.  

To install:



Click image to see an enlarged view

Fig. Apply a bead of silicone sealant in two places before installing the valve cover



Click image to see an enlarged view

Fig. Valve cover mounting fastener tightening sequence

  1. Clean all gasket material from the cover and head.
  2.  
  3. Before installing the new gasket(s), apply a 0.24 inch (6mm) bead of silicone sealant to the seam between the lower intake manifold and cylinder head.
  4.  
  5. Install the new gasket(s).
  6.  
  7. Install the valve cover onto the cylinder head in correct position, then install the mounting bolts. Tighten the mounting bolts in correct sequence to 54-70 inch lbs. (6-8 Nm).
  8.  
  9. If installing the left valve cover, perform the following steps:
    1. Install the nut and stud bolt, then install the EGR valve.
    2.  
    3. Connect the vacuum lines to the EGR valve.
    4.  
    5. Install the upper intake manifold.
    6.  

  10.  
  11. If installing the right valve cover, perform the following steps:
    1. Connect the spark plug wires.
    2.  
    3. Connect the hose to the vacuum reservoir.
    4.  
    5. Connect the cruise control actuator cable.
    6.  
    7. Connect the heater water hose.
    8.  
    9. Engage the engine control sensor wiring to the MAF sensor and alternator.
    10.  
    11. Connect the upper radiator hose.
    12.  
    13. Install the air cleaner outlet tube.
    14.  
    15. Refill the cooling system.
    16.  

  12.  
  13. Connect the negative battery cable.
  14.  

 
label.common.footer.alt.autozoneLogo