Mazda Car 2002-04

Camshaft, Bearings & Lifters 2

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Removal & Installation



1.8L (Bp) 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.


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



    Negative battery cable
     
    Timing belt
     
    Variable valve timing actuator and camshaft pulley. Hold the hexagonal part of the camshaft with a wrench to prevent the camshaft from turning and remove the actuator and pulley bolt.
     



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



    Click image to see an enlarged view

    Fig. Exploded view of the camshaft assembly and related components-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence--1.8L (BP) engine

  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
     

  2.  
  3. Lubricate the camshaft journals and lobes with clean engine oil.
  4.  
  5. Install the camshafts so the cam projections of cylinders 1 and 3 face in the direction as illustrated.

    Click image to see an enlarged view

    Fig. Install the camshafts so the cam projections of cylinders 1 and 3 face in the direction shown-1.8L (BP) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. When installing the variable valve timing actuator and camshaft pulley, make sure the knock pin and alignment marks are aligned as shown-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Check the Crankshaft position (CKP) sensor gap-1.8L (BP) engine

  6.  
  7. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
  8.  
  9. 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.
     

  10.  
  11. Make sure the camshaft is settled horizontally when the 2 bearing cap bolts at the number 3 journal are tightened.

    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.
     

  12.  
  13. Install the variable valve timing actuator and camshaft pulley as follows:
    1. Rotate the camshaft and face the knock pin to the position illustrated.
    2.  
    3. Install the camshaft so that the alignment mark of the pulley faces as illustrated.
    4.  
    5. Install the camshaft so the knock pin of the camshaft is connected to the camshaft knock pin hole of the actuator.
    6.  
    7. Hold the hexagonal part of the camshaft with a wrench to prevent the camshaft from turning and tighten the actuator and pulley bolt. Refer to the illustration for torque specifications.
    8.  

  14.  
  15. Install the remaining components in the reverse order of removal and inspect the Crankshaft position (CKP) sensor gap. Measure the gap between each 4 projections of the plate behind crankshaft pulley. The gap should be 0.020-0.059 inch (0.5-1.5mm). If not as specified, adjust.
  16.  

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

    negative battery cable
     
    timing belt
     
    Variable valve timing actuator and camshaft pulley. Hold the hexagonal part of the camshaft with a wrench to prevent the camshaft from turning and remove the actuator and pulley bolt.
     

  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
 
Lifters and adjustment shims, if necessary
 


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



Click image to see an enlarged view

Fig. Exploded view of the camshaft assembly and related components-1.8L (BP) engine



Click image to see an enlarged view

Fig. Camshaft cap bolt loosening sequence--1.8L (BP) engine

To install:

  1. Install or connect the following:

    Lifters in their original positions by lubricating them with engine oil
     

  2.  


NOTE
Verify that they move smoothly in their bore.

  1. Lubricate the camshaft journals and lobes with clean engine oil.
  2.  
  3. Install the camshafts so the cam projections of cylinders 1 and 3 face in the direction as illustrated.
  4.  
  5. Apply silicone sealant to the cylinder head on the front camshaft cap mating surfaces. Do not allow any sealant on the camshaft journals.
  6.  
  7. 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.
     

  8.  
  9. Make sure the camshaft is settled horizontally when the 2 bearing cap bolts at the number 3 journal are tightened.

    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.
     

  10.  
  11. Install the variable valve timing actuator and camshaft pulley as follows:
    1. Rotate the camshaft and face the knock pin to the position illustrated.
    2.  
    3. Install the camshaft so that the alignment mark of the pulley faces as illustrated.
    4.  
    5. Install the camshaft so the knock pin of the camshaft is connected to the camshaft knock pin hole of the actuator.
    6.  
    7. Hold the hexagonal part of the camshaft with a wrench to prevent the camshaft from turning and tighten the actuator and pulley bolt. Refer to the illustration for torque specifications.
    8.  

  12.  
  13. Install the remaining components in the reverse order of removal and inspect the Crankshaft position (CKP) sensor gap. Measure the gap between each 4 projections of the plate behind crankshaft pulley. The gap should be 0.020-0.059 inch (0.5-1.5mm). If not as specified, adjust.
  14.  


    Click image to see an enlarged view

    Fig. Install the camshafts so the cam projections of cylinders 1 and 3 face in the direction shown-1.8L (BP) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. When installing the variable valve timing actuator and camshaft pulley, make sure the knock pin and alignment marks are aligned as shown-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Check the Crankshaft position (CKP) sensor gap-1.8L (BP) engine


2.0L (FS) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Accelerator cable
     
    Fuel hose
     
    Ignition coil
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.
     

  10.  


    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-2.0L (FS) engines



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:

  1. Install or connect the following:

    camshafts making sure to lubricate the journals and lobes with clean engine oil. Place the camshafts onto the cylinder head facing the cam noses at the No. 1 and No. 3 cylinders as illustrated.
     

  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
     
    Hand tighten cap bolts marked 5, 5, 2 and 4, refer to the torque sequence illustration for location
     
    Cap bolts. Torque the bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.
     

  6.  
  7. Make sure the camshaft is settled horizontally when the 2 bearing cap bolts at the number 3 journal are tightened.

    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 0.012-0.027 inch (0.3-0.7mm.
     

  8.  
  9. Turn the camshafts until the dowel pins face straight up.
  10.  
  11. 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.
     
    Ignition coil
     
    Fuel hose
     
    Accelerator cable
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  


    Click image to see an enlarged view

    Fig. Install the camshafts so the cam noses are positioned at the No. 1 and No. 3 cylinders-2.0L (FS) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.0L (FS) engines


  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    NOTE
    Label the caps so they can be reinstalled in their original positions.



    Negative battery cable
     
    Timing belt
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Accelerator cable
     
    Fuel hose
     
    Ignition coil
     
    Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt.

    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-2.0L (FS) engines

     



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

  10.  

To install:

  1. Install or connect the following:

    Camshafts making sure to lubricate the journals and lobes with clean engine oil. Place the camshafts onto the cylinder head facing the cam noses at the No. 1 and No. 3 cylinders as illustrated.

    Click image to see an enlarged view

    Fig. Install the camshafts so the cam noses are positioned at the No. 1 and No. 3 cylinders-2.0L (FS) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.0L (FS) 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
     
    Hand tighten cap bolts marked 5, 5, 2 and 4, refer to the torque sequence illustration for location
     
    Cap bolts. Torque the bolts in 2-3 steps to 125 inch lbs. (14 Nm) in the proper sequence.
     

  6.  
  7. Make sure the camshaft is settled horizontally when the 2 bearing cap bolts at the number 3 journal are tightened.

    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 0.012-0.027 inch (0.3-0.7mm.
     

  8.  
  9. Turn the camshafts until the dowel pins face straight up.
  10.  
  11. 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.
     
    Ignition coil
     
    Fuel hose
     
    Accelerator cable
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Timing belt
     
    Negative battery cable
     

  12.  
  13. Fill and bleed the cooling system.
  14.  
  15. Change the oil and filter.
  16.  
  17. Run the engine and check for proper operation.
  18.  

 
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