Mazda Car 2005-06

Cylinder Head

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the battery and battery tray.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove the front suspension tower bar.
  10.  
  11. Remove the air cleaner.
  12.  
  13. Remove the dynamic chamber.
  14.  
  15. Remove the ignition coil.
  16.  
  17. Remove the drive belt.
  18.  
  19. Remove the CKP sensor.
  20.  
  21. Remove the P/S oil pump with the oil hose still connected and position the P/S oil pump so that it is out of the way.
  22.  
  23. Remove the timing chain.
  24.  
  25. Remove the wiper arm.
  26.  
  27. Remove the cowl grille.
  28.  
  29. Remove the side cowl grille.
  30.  
  31. Remove the service hole cover.
  32.  
  33. Disconnect the alternator, but do not remove it from the vehicle.
  34.  
  35. Remove the exhaust manifold.
  36.  
  37. Remove the OCV sensor, if equipped with variable valve timing.
  38.  
  39. Mark the camshaft cap locations so they may be reinstalled in their original positions.
  40.  
  41. Remove camshafts.
  42.  
  43. Mark the cylinder head bolt locations so they may be reinstalled in their original positions.
  44.  
  45. Loosen the cylinder head bolts in the sequence illustrated using two or three passes.
  46.  
  47. Remove the cylinder head.
  48.  
  49. Measure the length of the cylinder head bolts and replace any bolts that exceed the maximum length specification of 146. mm (5.77 in.).

    Click image to see an enlarged view

    Fig. Exploded view of the cylinder head and camshaft assemblies-MX-5 Miata



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-MX-5 Miata



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-MX-5 Miata



    Click image to see an enlarged view

    Fig. Measure the cylinder head bolt length-MX-5 Miata

  50.  

To install:

  1. Install the cylinder heads.
  2.  
  3. Install the cylinder head bolts in their original locations.
  4.  
  5. Tighten the cylinder head bolts in the sequence illustrated using 5 passes as follows:
    1. Step 1: Tighten to 5 Nm (44.3 in. lbs.)
    2.  
    3. Step 2: Tighten 13-17 Nm (10-12.5 ft. lbs.)
    4.  
    5. Step 3: Tighten 44-46 Nm (32.5-33.9 ft. lbs.)
    6.  
    7. Step 4: Tighten and additional 88-92 degrees.
    8.  
    9. Step 5: Tighten and additional 88-92 degrees.

      Click image to see an enlarged view

      Fig. Cylinder head bolt torque sequence-MX-5 Miata



      Click image to see an enlarged view

      Fig. Camshaft cap bolt torque sequence-MX-5 Miata

    10.  

  6.  
  7. Set the cam position of the number 1 cylinder to top dead center, install the camshafts, making sure to install the caps in their original locations.
  8.  
  9. Tighten the camshaft cap bolts using two to three steps in the sequence illustrated to 5-9 Nm (44.3-79.6 in. lbs.) and then to 14-17 Nm (10.4-12.5 ft. lbs.)
  10.  
  11. Install the remaining components in the reverse order of removal
  12.  
  13. Start the engine and inspect for leaks.
  14.  
  15. Check the ignition timing, idle speed and idle mixture.
  16.  

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing chain.
  6.  
  7. Remove the ignition coil.
  8.  
  9. Unbolt the alternator and move it aside with the connectors still attached.
  10.  
  11. Remove the front exhaust pipe.
  12.  
  13. Remove the intake manifold.
  14.  
  15. Disconnect the following components:

    Upper radiator hose
     
    Water and heater hose
     

  16.  
  17. Support the engine using an engine jack and attachment as shown in the illustration.

    Click image to see an enlarged view

    Fig. Support the engine using an engine jack and attachment as shown-Mazda6 and Mazdaspeed6 models

  18.  
  19. Remove the oil control valve.
  20.  
  21. Remove the camshafts.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  22.  
  23. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  24.  
  25. Once all the bolts have been removed, remove the cylinder head and gasket.

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-Mazda6 and Mazdaspeed6 models

  26.  

To install:

  1. If reusing old bolts, which is not recommended; measure the length of each head bolt at the locations illustrated. If any bolt exceeds 5.717-5.740 inch (145.2-145.8mm) replace the bolt.

    Click image to see an enlarged view

    Fig. Measure the length of each head bolt at the locations illustrated, if reusing the old bolts. If any bolt exceeds 5.717-5.740 inch (145.2-145.8mm) replace the bolt-Mazda6 models



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-Mazda6 and Mazdaspeed6 with the 2.3L (L3) engine

  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Install the cylinder head.
  6.  
  7. Apply clean engine oil to the bolt threads and seating faces.
  8.  
  9. Install new cylinder head bolts and torque in 2-3 steps, in sequence as follows:
    1. Step 1: Tighten the bolts in sequence to 27-97 inch lbs. (3-11 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence to 9.5-12.5 ft. lbs. (13-17 Nm).
    4.  
    5. Step 3: Tighten the bolts in sequence to 32-34.5 ft. lbs. (43-47 Nm).
    6.  
    7. Step 4: Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-92 degrees.
    8.  
    9. Step 5: Turn each bolt, in sequence, 85-92 degrees.
    10.  

  10.  
  11. Install the camshafts and caps in their original positions.
  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Change the oil and filter.
  18.  
  19. Run the engine and check for proper operation.
  20.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the water pump.
  10.  
  11. Remove the timing chain.
  12.  
  13. Support the engine using an engine jack and attachment.
  14.  
  15. Remove the water bypass tube stud bolt and bolt and disconnect the tube from the cylinder head.
  16.  
  17. Remove the camshaft(s).
  18.  
  19. Remove the rocker arm(s).
  20.  
  21. Remove the camshafts.
    NOTE
    If removing the right hand cylinder head and camshaft caps, remove thrust caps 1R and 5R first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps. If removing the left hand cylinder head and camshaft caps, remove thrust caps 1L and 6L first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps.

  22.  
  23. Loosen the camshaft caps using 7-8 passes in sequence after first removing the thrust caps to allow the camshafts to be slowly raised. Keep the caps in the order they were removed so they are re-installed in their original positions.
  24.  
  25. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  26.  
  27. Once all the bolts have been removed, remove the cylinder head and gasket.

    Click image to see an enlarged view

    Fig. If removing the right hand camshaft caps, remove thrust caps 1R and 5R first-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the right hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. If removing the left hand camshaft caps, remove thrust caps 1L and 6L first-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the left hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Cylinder head bolt loosening sequence-Mazda6 with the 3.0L (AJ) engine

  28.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-Mazda6 with the 3.0L (AJ) engine

  1. Install a new head gasket and the cylinder head.
  2.  
  3. Lubricate the cylinder head bolt threads.
  4.  
  5. Torque the cylinder head bolts in the proper sequence as follows:
    1. Step 1: Tighten the bolts in sequence 24-28 ft. lbs. (32-38 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence an additional 85-95 degrees.
    4.  
    5. Step 3: Loosen the bolts in sequence one full turn.
    6.  
    7. Step 4: Tighten the bolts in sequence 24-28 ft. lbs. (32-38 Nm).
    8.  
    9. Step 5: Tighten the bolts in sequence an additional 85-95 degrees.
    10.  
    11. Step 6: Tighten the bolts in sequence an additional 85-95 degrees.
    12.  

  6.  
  7. Install the camshafts in their original positions.
  8.  
  9. Install the left hand camshaft as follows:
    1. Place the crankshaft keyway at the 11 O-clock position by rotating the crankshaft clockwise.
    2.  
    3. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    4.  
    5. Position the mark on the intake camshaft to the 9 O-clock position as illustrated.
    6.  
    7. Position the mark on the exhaust camshaft to the 12 O-clock position.
    8.  
    9. Install the timing chain.
      NOTE
      Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

    10.  
    11. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1L and 6L, tighten the remaining caps.

      Click image to see an enlarged view

      Fig. When installing the left hand camshaft place the crankshaft keyway at the 11 O-clock position-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the left hand camshaft and position the mark on the intake camshaft to the 9 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda6 with the 3.0L (AJ) engine

    12.  

  10.  
  11. Install the right hand camshaft as follows:
    1. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    2.  
    3. Place the crankshaft keyway at the 3 O-clock position.
    4.  
    5. Position the mark on the exhaust camshaft to the 12 O-clock position by rotating the crankshaft clockwise.
    6.  
    7. Position the mark on the intake camshaft to the 3 O-clock position as illustrated.
    8.  
    9. Install the timing chain.
      NOTE
      Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

    10.  
    11. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1R and 5R, tighten the remaining caps.

      Click image to see an enlarged view

      Fig. When installing the right hand camshaft place the crankshaft keyway at the 3 O-clock position-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the right hand camshaft and position the mark on the intake camshaft to the 3 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Right side camshaft cap torque sequence-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Left side camshaft cap torque sequence-Mazda6 with the 3.0L (AJ) engine

    12.  

  12.  
  13. Install the water bypass tube.
  14.  
  15. Remove the engine jack and attachment.
  16.  
  17. Install the water pump.
  18.  
  19. Fill the cooling system.
  20.  
  21. Fill and bleed the cooling system.
  22.  
  23. Change the oil and filter.
  24.  
  25. Run the engine and check for proper operation.
  26.  

Mazdaspeed6
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing chain.
  6.  
  7. Unbolt the alternator and move it aside with the connectors still attached.
  8.  
  9. Remove the front exhaust pipe.
  10.  
  11. Remove the intake manifold.
  12.  
  13. Disconnect the following components:

    Upper radiator hose
     
    Water and heater hose
     

  14.  
  15. Support the engine using an engine jack and attachment as shown in the illustration.
  16.  
  17. Remove the oil control valve.
  18.  
  19. Remove the camshafts.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  20.  
  21. Loosen the cylinder head bolts using 2-3 passes in the sequence illustrated.
  22.  
  23. Once all the bolts have been removed, remove the cylinder head and gasket.
  24.  

To install:

  1. If reusing old bolts, which is not recommended; measure the length of each head bolt at the locations illustrated. If any bolt exceeds 5.700-5.720 inch (144.7-145.3mm) replace the bolt.
  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Install the cylinder head.
  6.  
  7. Apply clean engine oil to the bolt threads and seating faces.
  8.  
  9. Install new cylinder head bolts and torque in 2-3 steps, in sequence as follows:
    1. Step 1: Tighten the bolts in sequence to 27-97 inch lbs. (3-11 Nm).
    2.  
    3. Step 2: Tighten the bolts in sequence to 9.6-12.5 ft. lbs. (13-17 Nm).
    4.  
    5. Step 3: Tighten the bolts in sequence to 32-34.6 ft. lbs. (43-47 Nm).
    6.  
    7. Step 4: Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 88-92 degrees.
    8.  
    9. Step 5: Turn each bolt, in sequence, 88-92 degrees.
    10.  

  10.  
  11. Install the camshafts and caps in their original positions.
  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Change the oil and filter.
  18.  
  19. Run the engine and check for proper operation.
  20.  

 
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