Mazda Car 2002-04

Camshaft, Bearings & Lifters 1

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the camshaft and cylinder head components-Mazda 3 models

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the timing chain.
  6.  
  7. Remove the intake manifold.
  8.  
  9. Disconnect the following components:

    Warm Up-Three Way Converter (WU-TWC)
     
    Upper radiator hose
     
    Water and heater hose
     
    Wiring harness
     

  10.  
  11. Support the engine using an engine jack and attachment as shown in the illustration.

    Click image to see an enlarged view

    Fig. Support the engine using an engine jack and attachment as shown-Mazda 3 models

  12.  
  13. Remove the camshafts.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  14.  
  15. Loosen the camshaft cap bolts using 2-3 passes in the sequence illustrated.
  16.  
  17. Once all the bolts have been removed, remove the caps, keeping them in the original positions and remove the camshafts.

    Click image to see an enlarged view

    Fig. Camshaft cap bolt removal sequence-Mazda 3 models

  18.  

To install:

  1. Set the cam position of the number 1 cylinder at Top Dead center (TDC) and install the camshaft.
  2.  
  3. Temporarily install the camshaft caps in their original positions.
  4.  
  5. Tighten the camshaft cap bolt in two steps:
    1. Step 1: 44-71 inch lbs. (5-8 Nm).
    2.  
    3. Step 2 : 10.4-12.5 ft. lbs. (14-17 Nm).

      Click image to see an enlarged view

      Fig. Camshaft cap bolt tightening sequence-Mazda 3 models

    4.  

  6.  
  7. Remove the engine jack and attachment.
  8.  
  9. Connect the following components:

    Wiring harness
     
    Water and heater hose
     
    Upper radiator hose
     
    WU-TWC converter
     

  10.  
  11. Install the intake manifold.
  12.  
  13. Install the timing chain.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Change the oil and filter.
  20.  
  21. Run the engine and check for proper operation.
  22.  

1.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable.
     
    Power steering hose brackets from the cylinder head cover
     
    Spark plug wires and plug wire clips

    Click image to see an enlarged view

    Fig. Exploded view of the camshaft assemblies-1.5L engine

     
    Breather tube and Positive Crankcase Ventilation (PCV) valve from the cylinder head cover
     
    Cylinder head cover by loosening in 2-3 steps
     
    Accessory drive belts
     
    Water pump pulley
     
    Timing belt covers
     
    Timing belt
     
    Distributor
     
    Camshaft sprocket bolts by holding the camshaft with a wrench on the cast hexagon
     
    Camshaft sprockets

    Click image to see an enlarged view

    Fig. Front camshaft cap bolt loosening sequence-1.5L engine



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.5L engine

     
    Seal plate
     

  4.  
  5. Rotate the camshafts clockwise so the cams don't press on the tappets
  6.  
  7. Loosen the front camshaft cap bolts in 5-6 steps, starting on the 2 outside bolts and finishing on the 2 inside bolts.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Note the location of the numbers on top of the camshaft caps, so the caps can be reinstalled in their original positions.


    NOTE
    Identify and mark each lifter as it is removed so it can be reinstalled in the same position.



    Front camshaft bolts and caps
     



    Camshaft cap bolts in 5-6 steps
     
    Camshaft caps
     
    Camshafts
     
    Chain and oil seals from the camshafts
     
    Lifters and adjustment shims, if necessary
     

  10.  

To install:

  1. Install or connect the following:
    NOTE
    Verify that they move smoothly in their bore.


    NOTE
    Be sure none of the lobes are located directly on the tappets.



    Lifters in their original positions, lubricated with engine oil
     



    Chain adjuster between the camshafts
     
    Camshafts by lubricating the camshaft lobes and journals with engine oil
     

  2.  
  3. Align the camshaft gear and timing chain marks.

    Click image to see an enlarged view

    Fig. When installing the camshafts, align the marks on the camshaft gears with the colored/marked links of the chain-1.5L engine



    Click image to see an enlarged view

    Fig. Apply sealant in the positions shown before installing the camshaft bearing caps-1.5L engine



    Click image to see an enlarged view

    Fig. Tighten the camshaft cap bolts according to the sequence shown-1.5L engine

  4.  
  5. Apply silicone sealant to the cylinder head on the front camshaft caps mating surface. Do not get sealant on the camshaft journals.
  6.  
  7. Install the camshaft bearing caps in their original locations.
  8.  
  9. Hand tighten the camshaft cap bolts numbered: 5, 7, 2 and 4. Torque, in sequence, in 5-6 steps with a final torque of 100-125 inch lbs. (11-14 Nm).
  10.  
  11. Install or connect the following:

    New camshafts seals lubricated with engine oil, using a seal installer until the seals are flush with the edge of the camshaft cap
     
    Seal plate
     
    Camshaft sprockets
     
    Timing belt and timing belt covers
     
    Water pump pulley
     
    Accessory drive belts
     

  12.  
  13. Adjust the drive belt tension.
  14.  
  15. Apply silicone sealant to a new cylinder head cover gasket, and install the gasket on the cylinder head cover.
  16.  
  17. Apply silicone sealant to the cylinder head in the area adjacent to the front camshaft caps.
  18.  
  19. Install or connect the following:

    Distributor
     
    Cylinder head cover. Torque the bolts in 2 steps, by reversing of the loosening sequence, to 61-95 inch lbs. (7-11 Nm)
     
    Power steering hose brackets. Torque the bolts to 89 inch lbs. (10 Nm)
     
    Spark plug wires and clips
     
    Breather hose and PCV valve
     
    Adjust the valve clearance
     

  20.  

1.6L (Zm) And 1.8L (Fp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    negative battery cable
     
    Spark plug wires
     
    Spark plugs
     


    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.8L (FP) engines

    Cylinder head cover hoses, if equipped
     
    cylinder head cover bolts
     
    Cylinder head cover
     
    timing belt
     
    Camshaft by holding it with a wrench on the hexagon cast into the camshaft
     
    Sprocket bolts
     
    Sprockets
     

  4.  


NOTE
Label the caps so they can be reinstalled in their original positions.



Camshaft cap bolts by loosening in 2-3 steps in the sequence shown
 
Camshaft caps
 

To install:


CAUTION
Because there is little thrust clearance, the camshaft must be held in the horizontal position during installation. If not excessive force will be applied to the thrust area causing a burr on the receiving area of the cylinder head journal. Make sure to use the following procedure to avoid damage.

  1.  
  2. Install or connect the following:

    Lubricate the camshaft journals and lobes with clean engine oil
     
    Camshafts onto the head facing the cam noses at the no. 1 and 3 cylinders as illustrated. Make sure the camshaft sliding surface is free of sealant.
     

  3.  
  4. Apply a 0.04 inch (1mm) bead of silicone sealant to the areas illustrated in the illustration. Do not allow any sealant on the camshaft journals.
  5.  
  6. Install or connect the following:

    camshaft caps in their original positions
     
    Cap bolts and hand tighten bolts 5, 7, 2 and 4
     
    Cap bolts a few turns in the sequence illustrated
     

  7.  
  8. Make sure the camshaft settles horizontally when the bearing cap bolts at the number 3 journals are tightened. Torque the bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.

    new camshaft seal by lubricating it with engine oil. Tap the seal into position, using a seal installer, until it is recessed into the cylinder head 0.01 inch (0.4mm) on the 1.6L (ZM) engines and 0.012-0.027 inch (0.3-0.7mm) on1.8L (FP) engines.
     

  9.  
  10. Turn the camshafts until the dowel pins face straight up.
  11.  
  12. Install or connect the following:

    Camshaft sprockets. Torque the bolts to 44 ft. lbs. (60 Nm) by holding the camshaft with the wrench on the cast hexagon.
     
    remaining components
     

  13.  


    Click image to see an enlarged view

    Fig. Install the camshafts onto the head facing the cam noses at the no. 1 and 3 cylinders as shown-1.6L (ZM) and 1.8L (FP) engines



    Click image to see an enlarged view

    Fig. Apply silicone sealant to the cylinder head in the positions shown-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Apply silicone sealant to the cylinder head in the positions shown-1.8L (FP) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.6L (ZM) and 1.8L (FP) engines


1.6L (Zm) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Label the caps so they can be reinstalled in their original positions.



    Negative battery cable
     
    Spark plug wires
     
    Spark plugs

    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.6L (ZM) engines

     
    Cylinder head cover hoses, if equipped
     
    Cylinder head cover bolts
     
    Cylinder head cover
     
    Timing belt
     
    Camshaft by holding it with a wrench on the hexagon cast into the camshaft
     
    Sprocket bolts
     
    Sprockets
     



    Camshaft cap bolts by loosening in 2-3 steps in the sequence shown
     
    Camshaft caps
     

  4.  

To install:


CAUTION
Because there is little thrust clearance, the camshaft must be held in the horizontal position during installation. If not excessive force will be applied to the thrust area causing a burr on the receiving area of the cylinder head journal. Make sure to use the following procedure to avoid damage.

  1.  
  2. Install or connect the following:

    Lubricate the camshaft journals and lobes with clean engine oil
     
    Camshafts onto the head facing the cam noses at the no. 1 and 3 cylinders as illustrated. Make sure the camshaft sliding surface is free of sealant.

    Click image to see an enlarged view

    Fig. Install the camshafts onto the head facing the cam noses at the no. 1 and 3 cylinders as shown-1.6L (ZM)



    Click image to see an enlarged view

    Fig. Apply silicone sealant to the cylinder head in the positions shown-1.6L (ZM) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.6L (ZM) engines

     

  3.  
  4. Apply a 0.04 inch (1mm) bead of silicone sealant to the areas illustrated in the illustration. Do not allow any sealant on the camshaft journals.
  5.  
  6. Install or connect the following:

    Camshaft caps in their original positions
     
    Cap bolts and hand tighten bolts 5, 7, 2 and 4
     
    Cap bolts a few turns in the sequence illustrated
     

  7.  
  8. Make sure the camshaft settles horizontally when the bearing cap bolts at the number 3 journals are tightened. Torque the bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.

    New camshaft seal by lubricating it with engine oil. Tap the seal into position, using a seal installer, until it is recessed into the cylinder head 0.01 inch (0.4mm) on the 1.6L (ZM) engines and 0.012-0.027 inch (0.3-0.7mm) on 1.8L (FP) engines.
     

  9.  
  10. Turn the camshafts until the dowel pins face straight up.
  11.  
  12. Install or connect the following:

    Camshaft sprockets. Torque the bolts to 44 ft. lbs. (60 Nm) by holding the camshaft with the wrench on the cast hexagon.
     
    Remaining components
     

  13.  

1.6L, 1.8L And 2.0L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Label the caps so they can be reinstalled in their original positions.


    NOTE
    Identify and mark each lifter as it is removed so it can be reinstalled in the same position.



    Negative battery cable
     
    Spark plug wires
     
    Spark plugs

    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.8L (BP) and 2.0L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-1.6L and 1.8L (FP) engines

     
    Cylinder head cover hoses, if equipped
     
    Cylinder head cover bolts
     
    Cylinder head cover
     
    Timing belt
     
    Distributor
     
    Camshaft by holding it with a wrench on the hexagon cast into the camshaft
     
    Sprocket bolts
     
    Sprockets
     



    Camshaft cap bolts by loosening in 2-3 steps in the sequence shown
     
    Camshaft caps
     
    Lifters and adjustment shims, if necessary
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    Verify that they move smoothly in their bore.



    Lifters in their original positions by lubricating them with engine oil
     



    Camshafts by lubricating the journals and lobes with clean engine oil

    Click image to see an enlarged view

    Fig. Apply silicone sealant to the cylinder head in the positions shown-1.8L (BP) and 2.0L engines



    Click image to see an enlarged view

    Fig. Apply silicone sealant to the cylinder head in the positions shown-1.6L and 1.8L (FP) engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.8L (BP) and 2.0L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.6L and 1.8L (FP) engines

     

  2.  
  3. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
  4.  
  5. Install or connect the following:

    Camshaft caps in their original positions
     
    Cap bolts. Torque the bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence
     
    New camshaft seal by lubricating it with engine oil. Tap the seal into position, using a seal installer, until it is flush with the edge of the camshaft cap on 1.8L (BP) and 2.0L engines or recessed into the cylinder head 0.012-0.027 in. (0.3-0.7mm) on the 1.6L and 1.8L (FP) engine
     

  6.  
  7. Turn the camshafts until the dowel pins face straight up.
  8.  
  9. Install or connect the following:

    Camshaft sprockets. Torque the bolts to 44 ft. lbs. (60 Nm) by holding the camshaft with the wrench on the cast hexagon.
     
    Remaining components
     

  10.  

 
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