Mazda MPV Workshop Manual

1996 Mazda MPV Service Repair Manual

CYLINDER HEAD GASKET REPLACEMENT

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove the timing belt.
4. Remove the intake manifold assembly.
5. Remove in the order shown in the figure, referring to Removal Note.
6. Install in the reverse order of removal, referring to Installation Note.
7. Install the intake manifold assembly.
8. Install the timing belt.
9. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant.
10. Connect the negative battery cable.
11. Start the engine and
    1. check the engine oil and engine coolant leakage.
    2. check the ignition timing and idle speed.
12. Check the compression.

Removal Note Cylinder head mazda mpv

1. Loosen the cylinder head bolts in two or three steps in the order shown.
2. Remove the cylinder head.

Installation Note Cylinder head Mazda MPV

1. Measure the amount of oil control plug projection from the deck of the cylinder block.
   • Projection: 5.3-5.7 mm { 0.209-0.224 in }
2. Apply clean engine oil to new O-rings; and install them to the oil control plugs.
3. Thoroughly remove all dirt, oil, and other material from the top of the cylinder block.
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4. Turn the crankshaft clockwise and apply engine oil to the cylinder walls.
5. Place a new cylinder head gasket on the left bank with the L mark facing upward.
6. Place a new cylinder head gasket on the right bank with the R mark facing upward.
7. Install the cylinder head to the cylinder block.
8. Tighten the cylinder head bolts.
   1. Before installation, measure each bolt length. Replace if necessary.
      • Length IN : 107.7-108.3 mm { 4.25-4.26 in } EX: 137.7-138.3 mm { 5.43-5.44 in }
      • Maximum IN : 109 mm { 4.29 in } EX: 139 mm { 5.47 in }
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   2. Tighten the bolts in the order shown.
      • Tightening torque: 17.2-22.0 N-m { 1.75-2.25 kgfm , 12.7-16.2 ftlbf }
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   3. Put a paint mark on each bolt head.
   4. Using the mark as a reference, tighten the bolts 85°-95° in the sequence shown.
   5. Retighten each bolt another 85°-95° in the sequence shown.
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Cylinder head cover

1. Remove all old silicone sealant from the cylinder head and cylinder head cover.
2. Coat a new gasket with silicone sealant, and install it onto the cylinder head cover.
3. Install the cylinder head cover along with new seal washers.
   • Tightening torque: 3.5-4.4 N m { 35-45 kgfcm , 31-39 in lbf }
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HLA REMOVAL / INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the air intake hose and dynamic chamber.
3. Remove the timing belt.
4. Remove in the order shown in the figure, referring to Removal Note.
5. Install in the reverse order of removal, referring to Installation Note.
6. Install the dynamic chamber and air intake hose.
7. Install the timing belt.
8. Fill the engine with the specified amount and type of engine oil.
9. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant.
10. Connect the negative battery cable.
11. Start the engine and
    1. check the engine oil and engine coolant leakage.
    2. check the ignition timing and idle speed.
12. Turn off the engine and check the drive belt deflection.
13. Perform a road test.
14. Recheck the engine oil and coolant levels.

Removal Rocker arm and rocker arm shaft assembly

1. Loosen the bolts in two or three steps in the order shown.
2. Remove the rocker arm and rocker arm shaft assembly together with the bolts. Do not mix up the parts of the rocker arm and rocker arm shaft assembly.

HLA Mazda MPV

• Remove the HLA by hand. If this is difficult, remove it with pliers.
  • Caution: Do not remove the HLA unless necessary because oil leakage will occur if the O-ring is damaged.

Installation Note HLA Mazda MPV

1. Pour engine oil into the oil reservoir in the rocker arm.
2. Apply engine oil to the HLA.
3. Carefully install the HLA into the rocker arm.

Rocker arm and rocker arm shaft assembly

Caution: Be careful that the rocker arm shaft spring does not get caught between the shaft and mounting boss during installation.

1. Install the rocker arm and rocker arm shaft assembly.
2. Tighten the bolts in two or three steps in the order shown
   • Tightening torque: 18-26 Nm { 1.8-2.7 kgfm , 14-19 ft lbf }
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