Mazda Car 2002-04

Camshaft, Bearings & Lifters 5

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Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Timing belt
     
    Accelerator cable
     
    Spark plug wires
     
    Necessary wiring and hoses
     
    Intake manifold
     
    Cylinder head covers
     
    Distributor
     
    Camshaft sprocket bolt by holding the camshaft with a wrench on the hexagon cast into the camshaft
     
    Camshaft Sprocket

    Click image to see an enlarged view

    Fig. Front camshaft cap bolt loosening sequence-2.3L and 2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt loosening sequence-2.3L and 2.5L engines

     

  8.  
  9. Turn the camshaft, using a wrench on the cast hexagon, until the camshaft knock pin is aligned with the cylinder head marks.
    NOTE
    Do not remove the camshaft caps when the camshaft lobe is pressing on a lifter, as the thrust journal support may become damaged.

  10.  
  11. Loosen the front camshaft cap bolts in 5-6 steps, in the proper sequence. Bolt A is only on the right cylinder head. Remove the front camshaft cap.
  12.  
  13. Mark the position of the camshaft caps so they can be reinstalled in their original locations. Loosen the remaining camshaft cap bolts in 5-6 steps, in the proper sequence, then remove the caps.
  14.  
  15. Remove or disconnect the following:
    NOTE
    Identify and mark each lifter as it is removed so it can be reinstalled in the same position.



    Camshafts
     
    Lifters and adjustment shims, if necessary
     

  16.  

To install:

  1. Install or connect the following:
    NOTE
    The thrust plate positions for the right and left cylinder head camshafts are different.



    Lifters in their original positions lubricated with engine oil. Verify that they move smoothly in their bore
     
    Camshafts by lubricating the camshaft journals, lobes and gears with clean engine oil and aligning the timing marks
     



    Click image to see an enlarged view

    Fig. When installing the camshafts, ensure that the marks on the cam gears are aligned-2.3L and 2.5L engines



    Click image to see an enlarged view

    Fig. Put silicone sealant on the cylinder head at the positions shown-2.3L and 2.5L engines



    Click image to see an enlarged view

    Fig. Front camshaft cap bolt tightening sequence-2.3L and 2.5L engines



    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.3L and 2.5L engines

  2.  
  3. Be sure the camshaft cap and cylinder head surfaces are clean. Apply a small amount of sealant to the mating surface of the front camshaft cap on both cylinder heads and the rear exhaust camshaft cap on the left cylinder head. Do not get any sealant on the camshaft rotating surfaces.
  4.  
  5. Install or connect the following:
    NOTE
    On the right cylinder head, install the sprocket so the R mark can be seen and the timing mark aligns with the camshaft knock pin. On the left cylinder head, install the sprocket so the L mark can be seen and the timing mark aligns with the camshaft knock pin.



    Front camshaft caps and thrust plate caps. Torque the bolts until the cap seats fully to the cylinder head
     
    Remaining caps in their original locations. Torque the bolts in 5-6 steps to 126 inch lbs. (14 Nm), in the proper sequence
     
    New oil seals in the cylinder head using an installer
     
    New blind cap coated with sealant, tap it in place using a plastic hammer
     
    Camshaft sprockets
     



    Camshaft sprocket bolts lubricated with engine oil, by holding the camshaft with a wrench on the cast hexagon. Torque the bolt to 103 ft. lbs. (140 Nm)
     
    Cylinder head cover using a new gasket coated with sealant. Torque the bolts, in sequence, in 2-3 steps, to 78 inch lbs. (8.8 Nm)
     
    Ventilation pipe to the left cover
     
    Distributor using a new O-ring lubricated with engine oil
     
    Distributor with the blade fitting into the camshaft groove and loosely tighten the retaining bolt
     
    Intake manifold, using a new gasket, loosely tighten the bolts
     
    Instake manifold stay. Torque the bolts to 19 ft. lbs. (25 Nm)
     
    Intake manifold . Torque the bolts in 2-3 steps, to 19 ft. lbs. (25 Nm)
     
    Wiring, hoses and fuel lines
     
    Accelerator cable
     
    Throttle valve cables, if equipped
     
    Timing belt
     
    Negative battery cable
     

  6.  
  7. Fill the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

3.0L (Aj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the water pump.
  10.  
  11. Remove the timing chain.
  12.  
  13. Support the engine using an engine jack and attachment.
  14.  
  15. Remove the water bypass tube stud bolt and bolt and disconnect the tube from the cylinder head.
  16.  
  17. Remove the camshaft(s).
  18.  
  19. Remove the rocker arm(s).
  20.  
  21. Remove the camshafts.
  22.  


NOTE
If removing the right hand camshaft caps, remove thrust caps 1R and 5R first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps. If removing the left hand camshaft caps, remove thrust caps 1L and 6L first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps.

  1. Loosen the camshaft caps using 7-8 passes in sequence after first removing the thrust caps to allow the camshafts to be slowly raised. Keep the caps in the order they were removed so they are re-installed in their original positions.
  2.  


    Click image to see an enlarged view

    Fig. If removing the right hand camshaft caps, remove thrust caps 1R and 5R first-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the right hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. If removing the left hand camshaft caps, remove thrust caps 1L and 6L first-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the left hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda 6 with the 3.0L (AJ) engine


To install:

  1. Install the camshafts in their original positions.
  2.  
  3. Install the left hand camshaft as follows:
    1. Place the crankshaft keyway at the 11 O-clock position by rotating the crankshaft clockwise.
    2.  
    3. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    4.  
    5. Position the mark on the intake camshaft to the 9 O-clock position as illustrated.
    6.  
    7. Position the mark on the exhaust camshaft to the 12 O-clock position.
    8.  
    9. Install the timing chain.
    10.  

  4.  


NOTE
Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

  1. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1L and 6L, tighten the remaining caps.
  2.  



Click image to see an enlarged view

Fig. When installing the left hand camshaft place the crankshaft keyway at the 11 O-clock position-Mazda 6 with the 3.0L (AJ) engine



Click image to see an enlarged view

Fig. Install the left hand camshaft and position the mark on the intake camshaft to the 9 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine

  1. Install the right hand camshaft as follows:
    1. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    2.  
    3. Place the crankshaft keyway at the 3 O-clock position.
    4.  
    5. Position the mark on the exhaust camshaft to the 12 O-clock position by rotating the crankshaft clockwise.
    6.  
    7. Position the mark on the intake camshaft to the 3 O-clock position as illustrated.
    8.  
    9. Install the timing chain.
    10.  

  2.  


NOTE
Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

  1. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1R and 5R, tighten the remaining caps.
  2.  



Click image to see an enlarged view

Fig. When installing the right hand camshaft place the crankshaft keyway at the 3 O-clock position-Mazda 6 with the 3.0L (AJ) engine



Click image to see an enlarged view

Fig. Install the right hand camshaft and position the mark on the intake camshaft to the 3 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine



Click image to see an enlarged view

Fig. Right side camshaft cap torque sequence-Mazda 6 with the 3.0L (AJ) engine



Click image to see an enlarged view

Fig. Left side camshaft cap torque sequence-Mazda 6 with the 3.0L (AJ) engine

  1. Install the water bypass tube.
  2.  
  3. Remove the engine jack and attachment.
  4.  
  5. Install the water pump.
  6.  
  7. Fill the cooling system.
  8.  
  9. Fill and bleed the cooling system.
  10.  
  11. Change the oil and filter.
  12.  
  13. Run the engine and check for proper operation.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the water pump.
  10.  
  11. Remove the timing chain.
  12.  
  13. Support the engine using an engine jack and attachment.
  14.  
  15. Remove the water bypass tube stud bolt and bolt and disconnect the tube from the cylinder head.
  16.  
  17. Remove the camshaft(s).
  18.  
  19. Remove the rocker arm(s).
  20.  
  21. Remove the camshafts.
    NOTE
    If removing the right hand camshaft caps, remove thrust caps 1R and 5R first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps. If removing the left hand camshaft caps, remove thrust caps 1L and 6L first. Do not loosen any of the other cap bolts until the thrust caps are removed or you could damage the thrust caps.

  22.  
  23. Loosen the camshaft caps using 7-8 passes in sequence after first removing the thrust caps to allow the camshafts to be slowly raised. Keep the caps in the order they were removed so they are re-installed in their original positions.

    Click image to see an enlarged view

    Fig. If removing the right hand camshaft caps, remove thrust caps 1R and 5R first-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the right hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. If removing the left hand camshaft caps, remove thrust caps 1L and 6L first-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Loosen the left hand camshaft caps using 7-8 passes in this sequence after first removing the thrust caps-Mazda 6 with the 3.0L (AJ) engine

  24.  

To install:

  1. Install the camshafts in their original positions.
  2.  
  3. Install the left hand camshaft as follows:
    1. Place the crankshaft keyway at the 11 O-clock position by rotating the crankshaft clockwise.
    2.  
    3. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    4.  
    5. Position the mark on the intake camshaft to the 9 O-clock position as illustrated.
    6.  
    7. Position the mark on the exhaust camshaft to the 12 O-clock position.
    8.  
    9. Install the timing chain.
      NOTE
      Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

    10.  
    11. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1L and 6L, tighten the remaining caps.

      Click image to see an enlarged view

      Fig. When installing the left hand camshaft place the crankshaft keyway at the 11 O-clock position-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the left hand camshaft and position the mark on the intake camshaft to the 9 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine

    12.  

  4.  
  5. Install the right hand camshaft as follows:
    1. Install the camshaft and the caps in their original positions and hand tighten the bolts.
    2.  
    3. Place the crankshaft keyway at the 3 O-clock position.
    4.  
    5. Position the mark on the exhaust camshaft to the 12 O-clock position by rotating the crankshaft clockwise.
    6.  
    7. Position the mark on the intake camshaft to the 3 O-clock position as illustrated.
    8.  
    9. Install the timing chain.
      NOTE
      Tighten the camshaft journal thrust caps last to avoid damaging the thrust caps.

    10.  
    11. Tighten the camshaft caps using several passes to 71-106 inch lbs. (8-12 Nm). After adjust the camshaft endplay using the thrust caps 1R and 5R, tighten the remaining caps.

      Click image to see an enlarged view

      Fig. When installing the right hand camshaft place the crankshaft keyway at the 3 O-clock position-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the right hand camshaft and position the mark on the intake camshaft to the 3 O-clock and the exhaust camshaft to the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Right side camshaft cap torque sequence-Mazda 6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Left side camshaft cap torque sequence-Mazda 6 with the 3.0L (AJ) engine

    12.  

  6.  
  7. Install the water bypass tube.
  8.  
  9. Remove the engine jack and attachment.
  10.  
  11. Install the water pump.
  12.  
  13. Fill the cooling system.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Change the oil and filter.
  18.  
  19. Run the engine and check for proper operation.
  20.  

 
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