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Cylinder Head Gasket Replacement (VIN Y): Notes

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Replacement Part 

O-ring
Quantity: 2
Location of use: Water inlet pipe		 Gasket
Quantity: 1
Location of use: Flange		 Cylinder head gasket
Quantity: 1
Location of use: Cylinder head
O-ring
Quantity: 1
Location of use: Water pipe component		 - -

Oil and Chemical Type 

Engine oil
Type: Recommended oil		 Gear oil
Type: SAE 90 gear oil or equivalent		 Sealant
Type: LOCTITE 962T, 518, 272 or equivalent
Silicone sealant
Type: TB1217D or equivalent		 Coolant
Type: Recommended coolant		 -
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.
  • Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the "Fuel Line Safety Procedure" to prevent the fuel from spraying.
    • Fuel may cause irritation if it comes in contact with skin and eyes.
    • If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
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 terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. Remove the front under cover No. 1 and No. 2. (See FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .) (See FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  3. Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
  4. Drain the engine oil. (See ENGINE OIL REPLACEMENT (VIN Y) .)
  5. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT (VIN Y) .)
  6. Drain the water-cooled charge air cooler coolant. (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT (VIN Y) .)
  7. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION (VIN Y) .)
  8. Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (VIN Y) .)
    • Air hose
    • Air cleaner cover
    • Air cleaner element
    • Air cleaner case
    • Fresh-air duct
  9. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION (VIN Y) .)
  10. Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (VIN Y) .)
  11. Remove the turbocharger air outlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (VIN Y) .)
  12. Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION (VIN Y) .)
  13. Remove the EGR pipe No. 1. (See EGR PIPE REMOVAL/INSTALLATION (VIN Y) .)
  14. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION (VIN Y) .)
  15. Remove the WU-TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (VIN Y) .)
  16. Remove the dynamic pressure turbo. (See DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION (VIN Y) .)
  17. Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION (VIN Y) .)
  18. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION (VIN Y) .)
  19. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION (VIN Y) .)
  20. Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION (VIN Y) .)
  21. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION (VIN Y) .)
  22. Remove the oil pan. (See OIL PAN REMOVAL/INSTALLATION (VIN Y) .)
  23. Remove the timing chain and chain guide. (See TIMING CHAIN REMOVAL/INSTALLATION (VIN Y) .)
  24. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION (VIN Y) .)
  25. Disconnect the radiator hoses shown in the figure.
    G16379487Courtesy of MAZDA MOTORS CORP.
  26. Remove in the order indicated in the table. (See REMOVAL/INSTALLATION FIGURE .)
  27. Install in the reverse order of removal. (See REMOVAL/INSTALLATION FIGURE .)
  28. Refill with the specified type and amount of the engine oil. (See ENGINE OIL REPLACEMENT (VIN Y) .)
  29. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT (VIN Y) .)
  30. Start the engine, and inspect and adjust the following:
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