Mazda Car 2002-04

Rocker Arm (Valve) Cover 1

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Removal & Installation



1.5L, 1.6L, 1.8L And 2.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Power steering hose bracket, if necessary
     
    Spark plug wires
     
    Vent hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts, in sequence, to 80 inch lbs. (9 Nm)
     
    PCV hose
     
    Vent hose
     
    Spark plug wires
     
    Power steering hose bracket, if removed
     
    Negative battery cable
     

  2.  

1.6L (Zm) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug wires
     
    Vent hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:
  2.  
  3. Apply a 0.12-0.15 inch (3-4mm) bead of silicone sealant to cylinder head at the areas illustrated.
  4.  
  5. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm).
     
    Remaining components removed to facilitate the rocker arm cover removal
     
    Negative battery cable
     

  6.  


    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Tighten the rocker arm cover bolts in the sequence shown-1.6L (ZM) engine


1.8L (Bp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Upper radiator hose
     
    Water hose
     
    Oil pipe
     
    Oil Control Valve (OCV)
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:



Click image to see an enlarged view

Fig. Apply silicone sealant to cylinder head at the areas illustrated-1.8L (BP) engine

Temporarily tighten the cover bolts A -1.8L (BP) engine



Click image to see an enlarged view

Fig.



Click image to see an enlarged view

Fig. Tighten the rocker arm cover bolts in the sequence shown-1.8L (BP) engine



Click image to see an enlarged view

Fig. Tighten the OCV bolts in the sequence shown-1.8L (BP) engine



Click image to see an enlarged view

Fig. Hold the frame of the OCV valve filter and install the OCV so it is aligned with the projected part on the flange end of the oil pipe-1.8L (BP) engine

  1. Install or connect the following:

    Rocker arm cover with a new gasket.
     
    Temporarily tighten the cover boltsA
     

  2.  


CAUTION
When installing the OCV valve, be careful not to damage the O-ring, if damaged it may cause leaking.



OCV and tighten the bolts in the sequence illustrated
 

  1. Install the oil pipe as follows:
    1. Oil pipe. Hold the frame of the OCV valve filter and install the OCV so it is aligned with the projected part on the flange end of the oil pipe. Coat the new washer with clean engine oil and temporarily install the upper and side oil pipe and position the pipe.
    2.  
    3. using several passes to 95 inch lbs. (11 Nm).A
    4.  
    5. Tighten oil pipe boltsB
    6.  
    7. Tighten oil pipe boltsC
    8.  
    9. Tighten oil pipe bolts 1, 2, 3, 4 and 7 using several passes to 95 inch lbs. (11 Nm).
    10.  
    11. Tighten oil pipe bolt 5 using several passes to 17 ft. lbs. (23 Nm).
    12.  
    13. Tighten oil pipe bolt 6 using several passes to 34 ft. lbs. (47 Nm).
    14.  

  2.  
  3. Install or connect the following:

    Water hose
     
    Upper radiator hose
     
    Spark plug wires
     
    Power steering hose bracket, if removed
     
    Negative battery cable
     

  4.  


    Click image to see an enlarged view

    Fig. Tighten oil pipe bolts A and B using several passes to the specification in the text-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Tighten oil pipe bolts C using several passes to the specification in the text-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Tighten oil pipe bolts using several passes to the specification in the text-1.8L (BP) engine


1.8L (Fp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug wires
     
    Vent hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover bolts in the sequence illustrated
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  


    Click image to see an enlarged view

    Fig. Remove the valve cover bolts in sequence-1.8L (FP) engines


To install:

  1. Install or connect the following:
  2.  
  3. Apply a bead of silicone sealant to cylinder head at the areas illustrated.
  4.  
  5. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 86 inch lbs. (10 Nm).
     
    Remaining components removed to facilitate the rocker arm cover removal
     
    Negative battery cable
     

  6.  


    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-1.8L (FP) engine



    Click image to see an enlarged view

    Fig. Tighten the rocker arm cover bolts in the sequence shown-1.8L (FP) engine


2.0L (Fs) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Any components that would interfere with cover removal
     
    Rocker arm cover bolts in the sequence illustrated
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  


    Click image to see an enlarged view

    Fig. Remove the rocker arm cover bolts in the sequence shown-2.0L (FS) engine


To install:

  1. Apply silicone sealant to cylinder head at the areas illustrated.
  2.  
  3. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm).
     
    Remaining components removed to facilitate the rocker arm cover removal
     
    Negative battery cable
     

  4.  


    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-2.0L (FS) engine



    Click image to see an enlarged view

    Fig. Tighten the rocker arm cover bolts in the sequence shown-2.0L (FS) engine


2.0L (Lf) And 2.3L (L3) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug wires
     
    Vent hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:
  2.  
  3. Apply a 0.16-0.24 inch (4-7mm) bead of silicone sealant to cylinder head at the areas illustrated. Make sure to install the cover within 10 minutes of applying the sealant.
  4.  
  5. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 71-92 inch lbs. (8-10 Nm) on all Mazda 3 engines or 71-101inch lbs. (8-8-11.5 Nm) on Mazda 6 models equipped with the 2.3L (L3) engine.
     
    Remaining components removed to facilitate the rocker arm cover removal
     
    Negative battery cable
     

  6.  


    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-All Mazda 3 models and Mazda 6 models with the 2.3L (L3) engine models



    Click image to see an enlarged view

    Fig. Tighten the rocker arm cover bolts in the sequence shown-All Mazda 3 models and Mazda 6 models with the 2.3L (L3) engine models


2.3L (Kj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Ignition coils
     
    Vent hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:
  2.  
  3. Apply a 0.004-0.07 inch (1-2mm) bead of sealant to rocker arm cover.

    New rocker arm gasket
     

  4.  
  5. Apply a 0.059-0.098 inch (1.5-2.5mm) to the areas illustrated

    Rocker arm cover. Torque the bolts in sequence to 86 inch lbs. (10 Nm), then retighten in sequence to 86 inch lbs. (10 Nm).
     


    Click image to see an enlarged view

    Fig. Apply a 0.004-0.07 inch (1-2mm) bead of sealant to rocker arm cover-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Apply a 0.059-0.098 inch (1.5-2.5mm) to the areas shown-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Rocker arm cover bolt sequence-Millenia models equipped with the 2.3L (KJ) engine

    PCV hose
     
    Vent hose
     
    Ignition coils
     
    Negative battery cable
     

  6.  

2.3L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Ignition coils
     
    Vent hose
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts, in sequence, to 80 inch lbs. (9 Nm)
     
    PCV hose
     
    Vent hose
     
    Ignition coils
     
    Negative battery cable
     

  2.  

2.5L (Kl) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Any components that would interfere with cover removal
     
    Rocker arm cover bolts
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Apply silicone sealant to cylinder head at the areas illustrated.
  2.  
  3. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm) using 2 or 3 steps. Retighten the right hand cover number 5 and 6 bolts and the left hand cover number 6 and 7 bolts.
     
    Remaining components removed to facilitate the rocker arm cover removal
     
    Negative battery cable
     

  4.  


    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-2.5L (KL) engine



    Click image to see an enlarged view

    Fig. Tighten the rocker arm cover bolts in the sequence shown-2.5L (KL) engine


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Any components that would interfere with cover removal.
     
    Rocker arm cover bolts
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Apply silicone sealant to cylinder head at the areas illustrated.
  2.  
  3. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm) using 2 or 3 steps. Retighten the right hand cover number 5 and 6 bolts and the left hand cover number 6 and 7 bolts.
     
    Remaining components removed to facilitate the rocker arm cover removal
     
    Negative battery cable
     

  4.  


    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-2.5L (KL) engine



    Click image to see an enlarged view

    Fig. Tighten the rocker arm cover bolts in the sequence shown-2.5L (KL) engine


2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold stay bracket
     
    Vent hoses
     
    Spark plug wires
     
    Intake manifold
     
    Positive Crankcase Ventilation (PCV) hose
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts, in sequence, to 80 inch lbs. (9 Nm)
     
    PCV hose
     
    Intake manifold
     
    Spark plug wires
     
    Vent hose
     
    Intake manifold stay bracket and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  2.  

 
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