-Flat screwdriver.
-Phillips head screwdriver.
-Socket set (ratchets wrenches).
-Torque wrench.
-Head gasket set (which also includes head bolts).
-New water pump.
-Permatex RTV Silicone Gasket Maker.
-Threadlocker (blue).
-Clean rags and towels.
Parts:
-Engine coolant (mix of 50% coolant and 50% distilled water).
-Engine Oil.
-Spark plugs.
Instructions:
1. Disconnect Battery:
-Open the hood and remove the negative battery terminal using a 10 mm wrench.
2. Drain Engine Coolant:
-Locate the drain plug on the bottom of the radiator and open it using a flat screwdriver or a 10 mm wrench.
-Allow the coolant to drain completely into a drain pan.
3. Remove Belt:
-Locate and loosen the alternator and water pump belts using the appropriate wrenches.
-Remove belts.
4. Disconnect Radiator Hoses:
-Use pliers or a wrench to remove the radiator upper and lower hose.
5. Disconnect Engine Wiring:
-Locate and disconnect the following engine wiring harnesses:
- Fuel injectors.
- Ignition coils.
- Water temperature sensor.
- ECT (Engine Coolant Temperature) sensor.
6. Unbolt Intake and Exhaust Manifolds:
-Unbolt the intake manifold from the cylinder head.
-Unbolt the exhaust manifold from the cylinder head.
-Remove the manifolds from the engine compartment.
7. Remove Valve Covers:
-Use a Phillips head screwdriver to remove bolts that hold the valve covers.
-Remove the valve covers.
8. Remove Timing components:
- Set piston #1 to top dead center (TDC) on the compression stroke. Align timing belt tensioner pulley mark "P" with "V" mark on the timing belt cover.
- Loosen the timing belt tensioner pulley, and the timing belt pulley. The timing belt pulley is spring-loaded so when you loosen the nut it will pull back. Remove both from the engine compartment.
9. Unbolt Cylinder Head:
-Use a socket wrench to remove the cylinder head bolts.
-Remove the cylinder head from the engine block.
10. Remove Old Gasket and Clean Surface:
-Thoroughly clean the cylinder block and head using a shop towel and degreaser.
-Ensure that all old gasket residues are removed.
11. Apply New Head Gasket
-Apply a thin layer of Permatex RTV Silicone Gasket Maker to the head's surface where the gasket will sit.
-Carefully place the new head gasket on the cylinder block.
- Make sure that the gasket is properly aligned.
12. Tighten Head Bolts:
-Install the new head bolts and begin tightening them in a diagonal pattern (i.e., in a star pattern).
-Tighten the bolts to the recommended torque specifications, which can be found in the vehicle's service manual.
-Tighten the bolts in several passes, gradually increasing the torque until reaching the specified value.
13. Reinstall Timing components:
- Install timing belt pulley, timing belt tensioner pulley with its guide (if equipped).
- Hand tighten the bolt but do not tighten at this time.
14. Install Intake and Exhaust manifolds:
- Using new gaskets, install the intake and exhaust manifolds. Be careful not to over-tighten the manifold bolts. This will damage the manifold surface.
15. Reinstall Valve Covers:
- Ensure you are using new valve cover gaskets then reinstall valve covers.
16. Reattach Wiring:
- Reinstall and plug back all the wire harness previously removed
17. Reinstall Water Pump
-Install a new water pump, new gaskets and use silicon sealant around the edges to prevent leaks.
-Tighten all bolts.
18. Connect Radiator Hoses:
- Reinstall radiator hoses and clamps on to their proper connections.
19. Refill Coolant:
- Refill the cooling system with a mixture of 50% antifreeze and 50% distilled water.
20. Install Spark plugs:
- Since you have taken everything apart, this is a good time to change your spark plugs so you do not have to take off your intake manifold to change them later on.
21. Reinstall Belts:
- Reinstall belts. Remember to tighten the tensioner when installing the new belt. Refer to your vehicle's service manual for proper specifications.
22. Reconnect Battery:
- Reinstall negative terminal onto battery.
Final Step: Start your vehicle and let it run for a few minutes. Check for any leaks from the head gasket or any other places. If you notice any leaks, tighten and ensure all parts are properly sealed.
Note: These instructions are intended as a general guide and may vary depending on the specific model and year of your Mazda Millenia. Always refer to the vehicle's service manual for specific instructions and tightening specifications for your vehicle.
