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Cylinder Head Gasket Removal / Installation - 2.3L: Installation

WARNING: This page is about a different car, the 2007 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Do not use metal scrapers, wire brushes, power discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION:
  • Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE:
  • If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  1. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    CAUTION:
    • Do not use metal scrapers, wire brushes, power discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE:
    • Clean the sealing surface with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
    NOTE:
    • If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 1: Locating Silicone Gasket And Sealant Applying Point
    G04929193Courtesy of MAZDA MOTORS CORP.
  2. Apply silicone gasket and sealant to the locations shown.
    Fig 2: Locating Head Gasket
    G04929192Courtesy of MAZDA MOTORS CORP.
  3. Install the head gasket.
    Fig 3: Identifying Tightening Sequence Of Cylinder Head Bolts
    G04929195Courtesy of MAZDA MOTORS CORP.
  4. Install the cylinder head and lubricate the cylinder head bolts with clean engine oil. Install the cylinder head bolts and tighten the bolts in the sequence shown in five stages.
    • Stage 1: Tighten the bolts to 5 N.m {0.51 kgf.m 4 ft.lbf}.
    • Stage 2: Tighten the bolts to 15 N.m {1.5 kgf.m 11 ft.lbf}.
    • Stage 3: Tighten the bolts to 45 N.m {4.59 kgf.m 33 ft.lbf}.
    • Stage 4: Turn the bolts 90 degrees.
    • Stage 5: Turn the bolts an additional 90 degrees.
    Fig 4: Locating Coolant Bypass Hose Bracket
    G04929190Courtesy of MAZDA MOTORS CORP.
  5. Connect the coolant bypass hose.
  6. Connect the EGR coolant hose.
  7. Connect the EGR valve electrical connector.
    Fig 5: EGR Tube And Ground Strap With Torque Specifications
    G04929197Courtesy of MAZDA MOTORS CORP.
  8. Connect the EGR tube and the ground strap.
    Fig 6: Locating Positive Crankcase Ventilation (PCV) Hose Clip
    G04929189Courtesy of MAZDA MOTORS CORP.
  9. Install the PCV hose clips.
  10. Install the fuel injector supply manifold. See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL / INSTALLATION , .
  11. Install the exhaust manifold. See EXHAUST MANIFOLD REMOVAL / INSTALLATION - 2.3L , .
  12. Install the camshafts. See CAMSHAFTS REMOVAL / INSTALLATION - 2.3L , .
  13. Connect the battery. See BATTERY DISCONNECT .
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