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Home >> Mazda >> 2006 >> B4000 Base, Automatic >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine Mechanical [Service Information 4.0L] >> Cylinder Head Gasket Removal / Installation - 4.0L >> Removal Note >> Both cylinder heads

Both cylinder heads

  1. With the vehicle in neutral, position it on a hoist. See LIFTING .
  2. Release the fuel system pressure. See FUEL PRESSURE RELIEF .
  3. Drain the cooling system. See ENGINE COOLANT REPLACEMENT - 4.0L .
  4. Remove the intake manifold. See INTAKE MANIFOLD REMOVAL / INSTALLATION - 4.0L .
  5. Remove the cooling fan shroud. See FAN SHROUD REMOVAL / INSTALLATION - 4.0L .
  6. Remove the accessory drive belt. See DRIVE BELT REMOVAL / INSTALLATION - 4.0L  .
  7. Remove the LH valve cover. See VALVE COVER - LH REMOVAL / INSTALLATION - 4.0L  .
  8. Remove the RH valve cover. See VALVE COVER - RH REMOVAL/INSTALLATION - 4.0L  .
    Fig 1: Disconnecting Generator Electrical Connections
    G04307571Courtesy of MAZDA MOTORS CORP.
  9. Disconnect the generator electrical connections.
    Fig 2: Removing Generator Mounting Bracket And Generator
    G04307572Courtesy of MAZDA MOTORS CORP.
  10. Remove the generator mounting bracket and generator as an assembly.
    1. Remove the bolt and the drive belt tensioner.
    2. Remove the bolts and the generator mounting bracket.
    Fig 3: Disconnecting Engine Wiring Harness Electrical Connector
    G04307573Courtesy of MAZDA MOTORS CORP.
  11. Disconnect the engine wiring harness electrical connector and release the harness retainers.
    Fig 4: Removing Engine Wiring Harness Retainer
    G04307574Courtesy of MAZDA MOTORS CORP.
  12. Remove the engine wiring harness retainer.
    Fig 5: Disconnecting Crankshaft Position Sensor Electrical Connector
    G04307575Courtesy of MAZDA MOTORS CORP.
  13. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 6: Removing Wiring Anchors And Wiring
    G04307576Courtesy of MAZDA MOTORS CORP.
  14. Remove the wiring anchors and position the wiring aside. Discard the wiring anchors.
    Fig 7: Disconnecting Coolant Temperature Indicator Sender Unit And Engine Coolant Temperature Sensor Electrical Connectors
    G04307577Courtesy of MAZDA MOTORS CORP.
  15. Disconnect the coolant temperature indicator sender unit and the engine coolant temperature (ECT) sensor electrical connectors.
    Fig 8: Removing Coolant Bypass Hose Clamp
    G04307578Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The coolant bypass hose will be removed with the thermostat housing.
  16. Move the coolant bypass hose clamp off the coolant pump outlet.
    Fig 9: Removing Thermostat Housing And Coolant Bypass Hose
    G04307579Courtesy of MAZDA MOTORS CORP.
  17. Remove the bolts and the thermostat housing and coolant bypass hose.
    Fig 10: Removing Wiring Harness Retainer
    G04307580Courtesy of MAZDA MOTORS CORP.
  18. Remove the bolt and the wiring harness retainer.
    Fig 11: Removing Accessory Bracket
    G04307581Courtesy of MAZDA MOTORS CORP.
  19. Remove the bolts and position the accessory bracket aside.
    Fig 12: Disconnecting Wiring Harness Casing From LH Cylinder Head
    G04307582Courtesy of MAZDA MOTORS CORP.
  20. Disconnect the wiring harness casing from the LH cylinder head.
    Fig 13: Removing Oil Level Indicator Tube
    G04307583Courtesy of MAZDA MOTORS CORP.
  21. Remove the bolt and the oil level indicator tube.
    Fig 14: Disconnecting LH Spark Plug Wires From Spark Plugs
    G04307584Courtesy of MAZDA MOTORS CORP.
  22. Using the spark plug wire remover SST  , disconnect the LH spark plug wires from the spark plugs.
    Fig 15: Disconnecting Fuel Pressure Sensor Electrical And Vacuum Connectors
    G04307585Courtesy of MAZDA MOTORS CORP.
  23. Disconnect the fuel pressure sensor electrical and vacuum connectors.
    Fig 16: Removing Fuel Injection Supply Manifold
    G04307586Courtesy of MAZDA MOTORS CORP.
  24. Remove the fuel injection supply manifold.
    1. Remove the four bolts and disconnect the fuel supply tube from the fuel manifold. Position the fuel supply tube aside.
    2. Remove the four bolts and the supply manifold and the fuel injectors as an assembly.
    Fig 17: Removing Roller Followers
    G04307587Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Mark each of the roller followers to ensure it is installed in its original position during reassembly.
  25. Use the valve spring compressor SST  to remove the roller followers.
    Fig 18: Setting Number 1 Piston To TDC Using Crankshaft Timing Tool
    G04307588Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The crankshaft timing tool SST  must be installed on the damper and should contact the engine block. This positions the engine at top dead center (TDC).
  26. Using the crankshaft timing tool SST  , set the number 1 piston to TDC.

    27. RH cylinder head 

    Fig 19: Identifying RH Fender Well Splash Shield
    G04307589Courtesy of MAZDA MOTORS CORP.
  27. Remove the RH fender well splash shield.
    Fig 20: Identifying RH Camshaft Tensioner
    G04307590Courtesy of MAZDA MOTORS CORP.
  28. Remove the RH camshaft tensioner.
  29. Remove the RH exhaust manifold. See EXHAUST MANIFOLD RIGHT HAND REMOVAL / INSTALLATION - 4.0L .
    Fig 21: Removing Bracket
    G04307591Courtesy of MAZDA MOTORS CORP.
  30. Remove the bolt and the bracket.
    Fig 22: Removing RH Camshaft Sprocket Bolt
    G04307592Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
    NOTE:
    • If necessary, use the torque wrench extension SST  to remove camshaft sprocket bolt.
  31. Remove the RH camshaft sprocket bolt.
    Fig 23: Removing Chain Guide Bolt
    G04307593Courtesy of MAZDA MOTORS CORP.
  32. Remove the chain guide bolt.
    Fig 24: Removing RH Camshaft Sprocket From Cassette
    G04307594Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.
    NOTE:
    • Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
  33. Remove the RH camshaft sprocket from the cassette.
    Fig 25: Identifying Removal Sequence RH Cylinder Head Bolts
    G04307595Courtesy of MAZDA MOTORS CORP.
  34. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown, and remove the RH cylinder head.
    1. Discard the head gasket.
    2. Discard the cylinder head bolts.
  35. Clean the gasket mating surfaces.

    36. LH cylinder head 

  36. Remove the LH exhaust manifold. See EXHAUST MANIFOLD LEFT HAND REMOVAL / INSTALLATION .
    Fig 26: Removing Ground Strap
    G04307596Courtesy of MAZDA MOTORS CORP.
  37. Remove the bolt and the ground strap.
    Fig 27: Removing Engine Wiring Harness Pin-Type Retainer
    G04307597Courtesy of MAZDA MOTORS CORP.
  38. Remove the engine wiring harness pin-type retainer.
    Fig 28: Removing LH Hydraulic Chain Tensioner
    G04307598Courtesy of MAZDA MOTORS CORP.
  39. Remove the LH hydraulic chain tensioner.
    Fig 29: Removing Camshaft Sprocket Bolt
    G04307599Courtesy of MAZDA MOTORS CORP.
  40. Remove the camshaft sprocket bolt.
    Fig 30: Removing Chain Guide Bolt
    G04307600Courtesy of MAZDA MOTORS CORP.
  41. Remove the chain guide bolt.
    Fig 31: Holding Chain And Cassette With Rubber Band
    G04307601Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Remove the camshaft sprocket to prevent breaking the cassette and to gain clearance to remove the cylinder head.
    NOTE:
    • Hold the chain and cassette with a rubber band to aid in removal and prevent the chain from falling into the cylinder block.
  42. Remove the LH camshaft sprocket from the chain cassette.
    Fig 32: Identifying Removal Sequence LH Cylinder Head Bolts
    G04307602Courtesy of MAZDA MOTORS CORP.
  43. Remove the eight 12 mm (0.47 in) bolts and the two 8 mm (0.31 in) bolts in the sequence shown and remove the LH cylinder head.
    1. Discard the head gaskets.
    2. Discard the cylinder head bolts.
  44. Clean the gasket mating surfaces.
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