Cylinder Head Gasket Removal / Installation - 4.0L: Installation

LH cylinder head 

Fig 1: Positioning Cylinder Head Gasket

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1. Position the cylinder head gasket and the cylinder head.
   Fig 2: Identifying Tightening Sequence LH Cylinder Head 12mm Bolts

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   NOTE:

   • Cylinder head bolts are a torque-to-yield design. New bolts must be installed.
2. Install the eight 12 mm (0.47 in) bolts and tighten in the sequence shown in two stages.
   • Stage 1: 12 Nm {1.2 kgf-m, 9 ft-lbf}
   • Stage 2: 25 Nm {2.5 kgf-m, 18 ft-lbf}
   Fig 3: LH Cylinder Head 8mm Bolts With Torque Specifications

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3. Install the two 8 mm (0.31 in) bolts.
   Fig 4: Identifying Tightening Sequence LH Cylinder Head 12mm Bolts

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4. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown.
   • Stage 1: Tighten the bolts 90 degrees.
   • Stage 2: Tighten the bolts an additional 90 degrees.
   Fig 5: Installing LH Camshaft Sprocket On Camshaft

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5. Position the LH camshaft sprocket in the chain and install it on the camshaft.
   Fig 6: Installing Camshaft Sprocket Bolt

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   CAUTION:

   • The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
6. Install the camshaft sprocket bolt.
   Fig 7: Installing Chain Guide Bolt

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7. Install the chain guide bolt.
   Fig 8: Installing Ground Strap

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8. Install the ground strap and the bolt.
   Fig 9: Installing Engine Wiring Harness Pin-Type Retainer

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9. Install the engine wiring harness pin-type retainer.
10. Install the LH exhaust manifold. See EXHAUST MANIFOLD LEFT HAND REMOVAL / INSTALLATION

RH cylinder head 

Fig 10: Positioning RH Cylinder Head Gasket
Courtesy of MAZDA MOTORS CORP.
11. Position the cylinder head gasket and the cylinder head.
    Fig 11: Identifying Tightening Sequence LH Cylinder Head 12mm Bolts

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Cylinder head bolts are a torque-to-yield design. New bolts must be installed.
12. Install the eight 12 mm (0.47 in) bolts and tighten in the sequence shown in 2 stages.
    • Stage 1: 12 Nm {1.2 kgf-m, 9 ft-lbf}
    • Stage 2: 25 Nm {2.5 kgf-m, 18 ft-lbf}
    Fig 12: LH Cylinder Head 8mm Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
13. Install the two 8 mm (0.31 in) bolts.
    Fig 13: Identifying Tightening Sequence LH Cylinder Head 12mm Bolts

    Courtesy of MAZDA MOTORS CORP.
14. Tighten the eight 12 mm (0.47 in) bolts in two stages in the sequence shown.
    • Stage 1: Tighten the bolts 90 degrees.
    • Stage 2: Tighten the bolts an additional 90 degrees.
    Fig 14: Installing RH Camshaft Sprocket On Camshaft

    Courtesy of MAZDA MOTORS CORP.
15. Position the RH camshaft sprocket in the chain and install it on the camshaft.
    Fig 15: Installing RH Camshaft Sprocket Bolt

    Courtesy of MAZDA MOTORS CORP.
    CAUTION:

    • The camshaft sprocket must turn freely on the camshaft. DO NOT tighten the bolt.
16. Install the RH camshaft sprocket bolt.
    Fig 16: Installing Chain Guide Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
17. Install the chain guide bolt.
    Fig 17: Installing Bracket With Torque Specifications

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18. Install the bracket and the bolt.
19. Install the LH exhaust manifold. See EXHAUST MANIFOLD LEFT HAND REMOVAL / INSTALLATION .

    Both cylinder heads 

    CAUTION:

    • The RH camshaft sprocket bolt is a left-hand threaded bolt.
    NOTE:

    • Use the camshaft gear torque adapter SST  to loosen the camshaft sprocket bolt.
    Fig 18: Loosening RH Camshaft Sprocket Bolt

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20. If necessary, loosen the RH camshaft sprocket bolt.
    Fig 19: Installing Camshaft Holding Tool SST And Adapter SST On Front Of RH Cylinder Head

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • The camshaft timing slots are off-center.
21. Position the camshaft timing slots below the center-line of the camshaft and install the camshaft holding tool SST  and adapter SST  on the front of the RH cylinder head.
    Fig 20: Identifying RH Fender Well Splash Shield

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22. Remove the RH fender well splash shield.
    Fig 21: Removing RH Camshaft Tensioner

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23. Remove the RH camshaft tensioner.
    Fig 22: Installing Camshaft Sprocket

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    NOTE:

    • Leave the top two clamp bolts loose.
24. Install the camshaft sprocket holding tool SST  and adapter SST  on the rear of the RH cylinder head.
    Fig 23: Installing Timing Chain Tensioner SST

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25. Install the timing chain tensioner SST  .
    Fig 24: Tightening Camshaft Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    CAUTION:

    • The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
    NOTE:

    • If necessary, use torque wrench extension SST  to tighten the camshaft sprocket bolt.
26. Tighten the bolts.
    1. Tighten the camshaft sprocket holding tool SST top two clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt.
    Fig 25: Installing RH Camshaft Tensioner With Torque Specifications

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27. Install the RH camshaft tensioner.
    Fig 26: Identifying RH Fender Well Splash Shield

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28. Install the RH fender well splash shield.
    Fig 27: Removing LH Camshaft Tensioner

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29. Remove the LH camshaft tensioner.
    Fig 28: Loosening LH Camshaft Sprocket Bolt

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30. If necessary, loosen the LH camshaft sprocket bolt.
    Fig 29: Installing Camshaft Sprocket Holding Tool SST

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Leave the top two special tool clamp bolts loose.
31. Install the camshaft sprocket holding tool SST  and adapter SST  on the front of the LH cylinder head.
    Fig 30: Installing Camshaft Holding Tool SST And Adapter SST On Rear Of LH Cylinder Head

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • The camshaft timing slots are off-center.
32. Position the camshaft timing slots below the center-line of the camshaft and install the camshaft holding tool SST  and adapter SST  on the rear of the LH cylinder head.
    Fig 31: Installing Timing Chain Tensioner SST

    Courtesy of MAZDA MOTORS CORP.
33. Install the timing chain tensioner SST  .
    Fig 32: Tightening Camshaft Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
34. Tighten the bolts.
    1. Tighten the camshaft sprocket holding tool SST top two clamp bolts to 10 Nm (89 lb-in).
    2. Tighten the camshaft bolt.
    Fig 33: Installing LH Camshaft Tensioner With Torque Specifications

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35. Install the LH camshaft tensioner.
    Fig 34: Installing Camshaft Roller Followers

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Install each roller follower in its original position.
36. Using the valve spring compressor SST  , install the camshaft roller followers.
    Fig 35: Installing Fuel Injection Supply Manifold With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
37. Install the fuel injection supply manifold.
    1. Install the fuel injection supply manifold and the fuel injectors as an assembly.
    2. Install the fuel supply tube to the fuel manifold.
    Fig 36: Connecting Fuel Pressure Sensor Electrical Connector

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38. Connect the fuel pressure sensor electrical connector.
39. Connect the LH spark plug wires to the spark plugs.
    Fig 37: Installing Oil Level Indicator Tube With Torque Specifications

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40. Install the oil level indicator tube and the bolt.
    Fig 38: Connecting Wiring Harness Casing To LH Cylinder Head

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41. Connect the wiring harness casing to the LH cylinder head.
    Fig 39: Installing Accessory Bracket Bolts With Torque Specifications

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42. Install the accessory bracket and the bolts.
    Fig 40: Installing Wiring Harness Clip Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
43. Position the wiring harness clip and install the bolt.
    Fig 41: Installing Thermostat Housing With Torque Specifications

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44. Install the thermostat housing and the bolts with the coolant bypass hose.
    Fig 42: Connecting Coolant Bypass Hose Clamp

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45. Connect the coolant bypass hose clamp.
    Fig 43: Connecting Water Temperature Indicator Sender Unit And Engine Coolant Temperature Sensor Electrical Connectors

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46. Connect the water temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
    Fig 44: Securing Wiring Anchors

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47. Secure the new wiring anchors.
    Fig 45: Connecting Crankshaft Position Sensor Electrical Connector

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48. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 46: Attaching Engine Wiring Harness Retainer

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49. Attach the engine wiring harness retainer.
    Fig 47: Connecting Wiring Harness Retainers And Electrical Connector

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50. Attach the wiring harness retainers and connect the electrical connector
    Fig 48: Installing Generator Mounting Bracket And Generator With Torque Specifications

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51. Install the generator mounting bracket and generator as an assembly.
    1. Position the generator bracket and install the bolts.
    2. Position the drive belt tensioner and install the bolt.
    Fig 49: Connecting Generator Electrical Connections With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
52. Connect the generator electrical connections.
53. Install the RH valve cover. See VALVE COVER - RH REMOVAL / INSTALLATION - 4.0L  .
54. Install the LH valve cover. See VALVE COVER - LH REMOVAL / INSTALLATION - 4.0L  .
55. Install the accessory drive belt. See DRIVE BELT REMOVAL / INSTALLATION - 4.0L  .
56. Install the cooling fan shroud. See FAN SHROUD REMOVAL / INSTALLATION - 4.0L .
57. Install the intake manifold. See INTAKE MANIFOLD REMOVAL / INSTALLATION - 4.0L .
58. Fill and bleed the cooling system. See ENGINE COOLANT REPLACEMENT - 4.0L .