Mazda MPV 1999-06

Cylinder Head

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Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Battery and tray
     
    Accessory drive belt
     
    Water pump and drive pulley
     
    Intake manifold
     
    Power steering pump
     
    Intake Manifold Runner Control (IMRC) actuator
     
    Spark plug wires
     
    Ignition coil
     
    Heated Oxygen (HO2S) sensor connectors
     
    Exhaust front pipe
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Exhaust manifolds
     
    Oil pan
     
    Alternator
     
    A/C compressor
     
    Valve covers
     
    Front cover
     
    Timing chains
     
    Camshafts
     
    Cylinder heads. Loosen the bolts in several passes and in the sequence shown.
     

  10.  


    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-2.5L and 3.0L engine


To install:


NOTE
The cylinder head bolts are a torque-to-yield design and must be replaced.

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 28-31 ft. lbs. (37-43 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Loosen one full turn.
    6.  
    7. Step 4: 28-31 ft. lbs. (37-43 Nm).
    8.  
    9. Step 5: Plus 90 degrees.
    10.  
    11. Step 6: Plus 90 degrees.
    12.  

  2.  
  3. Install or connect the following:

    Camshafts
     
    Timing chains
     
    Front cover
     
    Valve covers
     
    A/C compressor
     
    Alternator
     
    Oil pan
     
    Exhaust manifolds
     
    EGR pipe
     
    Exhaust front pipe
     
    HO2S sensor connectors
     
    Ignition coil
     
    Spark plug wires
     
    IMRC actuator
     
    Power steering pump
     
    Intake manifold
     
    Water pump and drive pulley
     
    Accessory drive belt
     
    Battery and tray
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  


    Click image to see an enlarged view

    Fig. Cylinder head torque sequence-2.5L and 3.0L engines


  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Battery and tray
     
    Accessory drive belt
     
    Water pump and drive pulley
     
    Intake manifold
     
    Power steering pump
     
    Intake Manifold Runner Control (IMRC) actuator
     
    Spark plug wires
     
    Ignition coil
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust front pipe
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Exhaust manifolds
     
    Oil pan
     
    Alternator
     
    A/C compressor
     
    Valve covers
     
    Front cover
     
    Timing chains
     
    Camshafts
     
    Cylinder heads. Loosen the bolts in several passes and in the sequence shown.

    Click image to see an enlarged view

    Fig. Left cylinder head loosening sequence-2.5L engine



    Click image to see an enlarged view

    Fig. Right cylinder head loosening sequence-2.5L engine

     

  10.  

To install:


NOTE
The cylinder head bolts are a torque-to-yield design and must be replaced.

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 28-31 ft. lbs. (37-43 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  
    5. Step 3: Loosen one full turn
    6.  
    7. Step 4: 28-31 ft. lbs. (37-43 Nm)
    8.  
    9. Step 5: Plus 90 degrees
    10.  
    11. Step 6: Plus 90 degrees
    12.  

  2.  
  3. Install or connect the following:

    Camshafts
     
    Timing chains
     
    Front cover
     
    Valve covers
     
    A/C compressor
     
    Alternator
     
    Oil pan
     
    Exhaust manifolds
     
    EGR pipe
     
    Exhaust front pipe
     
    HO 2 S sensor connectors
     
    Ignition coil
     
    Spark plug wires
     
    IMRC actuator
     
    Power steering pump
     
    Intake manifold
     
    Water pump and drive pulley
     
    Accessory drive belt
     
    Battery and tray
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

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

    Battery and tray
     
    Accessory drive belt
     
    Water pump and drive pulley
     
    Intake manifold
     
    Power steering pump
     
    Intake Manifold Runner Control (IMRC) actuator
     
    Spark plug wires
     
    Ignition coil
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Exhaust front pipe
     
    Exhaust Gas Recirculation (EGR) pipe
     
    Exhaust manifolds
     
    Oil pan
     
    Alternator
     
    A/C compressor
     
    Valve covers
     
    Front cover
     
    Timing chains
     
    Camshafts
     
    Cylinder heads. Loosen the bolts in several passes and in the sequence shown.

    Click image to see an enlarged view

    Fig. Left cylinder head loosening sequence-2.5L engine



    Click image to see an enlarged view

    Fig. Right cylinder head loosening sequence-2.5L engine

     

  10.  

To install:


NOTE
The cylinder head bolts are a torque-to-yield design and must be replaced.

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 28-31 ft. lbs. (37-43 Nm)
    2.  
    3. Step 2: Plus 90 degrees
    4.  
    5. Step 3: Loosen one full turn
    6.  
    7. Step 4: 28-31 ft. lbs. (37-43 Nm)
    8.  
    9. Step 5: Plus 90 degrees
    10.  
    11. Step 6: Plus 90 degrees
    12.  

  2.  
  3. Install or connect the following:

    Camshafts
     
    Timing chains
     
    Front cover
     
    Valve covers
     
    A/C compressor
     
    Alternator
     
    Oil pan
     
    Exhaust manifolds
     
    EGR pipe
     
    Exhaust front pipe
     
    HO 2 S sensor connectors
     
    Ignition coil
     
    Spark plug wires
     
    IMRC actuator
     
    Power steering pump
     
    Intake manifold
     
    Water pump and drive pulley
     
    Accessory drive belt
     
    Battery and tray
     

  4.  
  5. Fill the crankcase to the correct level.
  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Accessory drive belt
     
    Water pump and drive pulley
     
    Timing chains
     
    No.3 engine mount rubber and joint bracket
     
    Ventilation pipe
     
    Water bypass tube
     
    Camshafts
     

  10.  


NOTE
Remove the Nos. 1 and 5 caps first. Don-t loosen any other cap bolts until these caps are removed.



Rocker arms
 
Cylinder heads. Loosen the bolts in several passes and in the sequence shown.
 

To install:

  1. Installation is the reverse of removal. Observe the following torques:
  2.  


NOTE
The cylinder head bolts are a torque-to-yield design and must be replaced.

  1. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 24-28 ft. lbs. (32-38 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Loosen one full turn.
    6.  
    7. Step 4: 24-28 ft. lbs. (32-38 Nm).
    8.  
    9. Step 5: Plus 90 degrees.
    10.  
    11. Step 6: Plus 90 degrees.
    12.  

  2.  



Click image to see an enlarged view

Fig. Exploded view of the cylinder head components-3.0L engine

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Spark plug wires
     
    Distributor
     
    Accessory drive belts
     
    Cooling fan and shroud
     
    Upper radiator hose
     
    Front cover
     
    Timing belt. Refer to the Timing Belt unit repair section.
     
    Intake manifold
     
    Exhaust manifolds
     
    Positive Crankcase Ventilation (PCV) valve and hose
     
    Valve covers
     
    Cylinder heads

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.0L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Head gasket positioning-3.0L engine

  1. Measure the cylinder head bolts. Replace any that exceed the following specifications:

    Intake side: 4.29 inches (109mm)
     
    Exhaust side: 5.47 inches (139mm)
     

  2.  
  3. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 13-16 ft. lbs. (17-22 Nm)
    2.  
    3. Step 2: Plus 85-95 degrees
    4.  
    5. Step 3: Plus 85-95 degrees
    6.  

  4.  
  5. Install or connect the following:

    Valve covers
     
    PCV valve and hose
     
    Exhaust manifolds
     
    Intake manifold
     
    Timing belt
     
    Front cover
     
    Upper radiator hose
     
    Cooling fan and shroud
     
    Accessory drive belts
     
    Distributor
     
    Spark plug wires
     
    Air intake assembly
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine and check for leaks.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Remove the Nos. 1 and 5 caps first. Don-t loosen any other cap bolts until these caps are removed.



    Accessory drive belt
     
    Water pump and drive pulley
     
    Timing chains
     
    No.3 engine mount rubber and joint bracket
     
    Ventilation pipe
     
    Water bypass tube
     
    Camshafts
     



    Rocker arms
     
    Cylinder heads. Loosen the bolts in several passes and in the sequence shown.

    Click image to see an enlarged view

    Fig. Cylinder head loosening sequence-3.0L engine

     

  10.  

To install:

Click image to see an enlarged view

Fig. Cylinder head torque sequence-3.0L engine

  1. Installation is the reverse of removal. Observe the following torques:
    NOTE
    The cylinder head bolts are a torque-to-yield design and must be replaced.

  2.  
  3. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows:
    1. Step 1: 24-28 ft. lbs. (32-38 Nm).
    2.  
    3. Step 2: Plus 90 degrees.
    4.  
    5. Step 3: Loosen one full turn.
    6.  
    7. Step 4: 24-28 ft. lbs. (32-38 Nm).
    8.  
    9. Step 5: Plus 90 degrees.
    10.  
    11. Step 6: Plus 90 degrees.
    12.  

  4.  

 
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