Mazda CX-5 Service & Repair Manual: Cylinder Head Gasket Replacement

WARNING:

• A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.

• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”..

CAUTION:

• If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.

1. Disconnect the negative battery cable..

2. Remove the plug hole plate..

3. Remove the ignition coil/ion sensors..

4. Remove the front under cover No.2..

5. Remove the splash shield..

6. Remove the drive belt..

7. Drain the engine oil..

8. Drain the engine coolant..

9. Remove the intake manifold..

10. Set aside the exhaust manifold to the vehicle rear..

11. Disconnect the radiator hose (upper, lower).

12. Remove the vacuum pump..

13. Remove the high pressure fuel pump and rear housing..

14. Disconnect the heater hose from the water outlet and water inlet pipe.

15. Remove the oil pan..

16. Remove the timing chain and chain guide..

17. Remove the OCV..

18. Remove in the order indicated in the table.

19. Install in the reverse order of removal.

20. Refill with the specified type and amount of the engine oil..

21. Refill the engine coolant..

22. Start the engine, and inspect and adjust the following:

• Leakage of engine oil, engine coolant.

• Runout and contact of pulley and belt.

• Ignition timing, idle speed and idle mixture..

• Compression pressure.

Camshaft Removal Note

1. Loosen the camshaft cap installation bolts in a few passes in the order shown in the figure and remove the camshaft caps.

2. Remove the camshaft.

Rocker Arm Removal Note

1. Keep the rocker arms in the order of removal to enable reassembly in their original positions.

Cylinder Head Removal Note

1. Temporarily install the oil pan to support the engine from under the vehicle.

CAUTION:

• To prevent deformation of the oil pan, support the engine using the following methods.

• When using an engine lifter, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan to support the oil pan.

• When using a garage jack, place rubber of appropriate size (approx. 20 mm {0.79 in} thickness) on a batten which is large enough to cover the oil pan to support the oil pan.

2. Support the engine (oil pan) using a commercially available engine lifter or garage jack.

3. Remove the chain on the SST

that suspended the engine and set it aside.

4. Loosen the cylinder head installation bolts in two or three passes in the order shown in the figure and remove them.

5. Remove the cylinder head.

Cylinder Head Installation Note

CAUTION:

• If the following condition is met, replace the cylinder head bolts.

• Length exceeds maximum specification

Cylinder head bolt length L

• 145.2—145.8 mm {5.717—5.740 in}

Cylinder head bolt length L maximum

• 146.5 mm {5.767 in}

1. When a cylinder head bolt is reused, apply engine oil to any part of the following:

• Bolt surface

• Cylinder head seating surface

2. Tighten the cylinder head bolts in the order shown in the following 4 steps.

Tightening torque

• Step 1: 13—17 N·m {133—173 kgf·cm, 116—150 in·lbf}

• Step 2: 43—47 N·m {4.4—4.7 kgf·m, 32—34 ft·lbf}

• Step 3: 85—95°

• Step 4: 85—95°

3. Install the chain for the SST

which was set aside and secure the engine.

4. Remove the engine lifter or garage jack.

5. Remove the temporarily assembled oil pan.

Rocker Arm Installation Note

1. Apply engine oil to the HLAs and the end of the valve stems.

2. Install the rocker arms to the same positions as before removal.

Camshaft Installation Note

1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the cylinder head.

CAUTION:

• Apply 0.05 ml {0.05 cc, 0.003 in3} or less of oil to journal No.6.

2. Install the camshaft with cylinder No.1 cam aligned to the TDC position as shown in the figure.

3. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the camshaft.

4. Apply adhesive agent (Loctite 962T) around journal No.6 of the cylinder head or the exhaust-side rear camshaft cap.

CAUTION:

• Verify that there is no adhesive agent on the journal.

Adhesive agent bead width

• 0.5—1.5 mm {0.02—0.05 in}

5. Install the camshaft caps in the marked number order, and temporarily tighten the camshaft cap installation bolts in two or three passes evenly.

6. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure.

Tightening torque

• First step: 3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf}

• Second step: 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Water Inlet Pipe Installation Note

CAUTION:

• Do not apply oil (engine oil, ATF etc.) to the O-ring of the water inlet pipe. Otherwise, the O-ring could swell causing a seal malfunction.

1. Clean away the sealant adhering to the bolt hole on the cylinder block side of the water inlet pipe stay.

2. Apply engine coolant to the O-ring.

3. Install the O-ring to the water inlet pipe.

4. Insert the water inlet pipe into the water pump being careful not to damage the O-ring.

5. Install the water inlet pipe gasket with the gasket projection facing the direction shown in the figure.

6. Tighten the bolts in the order shown in the figure.