Mazda Car 2002-04

Oil Pan 1

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the oil pan and related components-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery cover and disconnect the negative battery cable.
  4.  
  5. Remove the engine under cover and splash shield as an assembly.
  6.  
  7. Remove the right front wheel.
  8.  
  9. Remove the plug hole plate.
  10.  
  11. Drain the engine oil.
  12.  
  13. Remove the drive belt.
  14.  
  15. Remove the coolant reservoir and position aside with the lines attached.
  16.  
  17. Remove the A/C compressor and position aside with the lines attached.
  18.  
  19. Remove the ignition coil and position the accelerator cable bracket aside.
  20.  
  21. Remove the Crankshaft Position (CKP) sensor.
  22.  
  23. Remove the engine front cover. Refer to the timing chain removal procedure in this section.
  24.  
  25. Remove the dipstick tube pipe and O-ring.
  26.  
  27. Remove the oil pan bolts and use a separator tool such as the one illustrated to separate the oil pan from the block.
  28.  
  29. Remove the oil pan.

    Click image to see an enlarged view

    Fig. Use a separator tool such as the one illustrated to separate the oil pan from the block-2.0L (LF) and 2.3L (L3) engines

  30.  

To install:

  1. Clean the oil pan mating surfaces.
  2.  
  3. Apply a 0.087-0.126 inch (2.2-3.2mm) bead of sealant around the perimeter of the oil pan as illustrated.
  4.  
  5. Use a square ruler to align the oil pan and the block junction side on the engine front cover side as illustrated.
  6.  
  7. Install the oil pan within 5 minutes of applying the sealant.
  8.  
  9. Install the lower oil pan bolts and tighten in sequence to 12.6-16.9 ft. lbs. (17-23 Nm) and the oil pan-to-transaxle bolts to 23-38 ft. lbs. (32-52 Nm).
  10.  
  11. When installing the CKP sensor perform the following:
    1. Remove the cylinder block lower blind plug.
    2.  
    3. Install tool 49 JE01 061.
    4.  
    5. Turn the crankshaft clockwise until the crankshaft is in the number 1 cylinder Top Dead Center position (the balance weight should be attached to tool 49 JE01 061).
    6.  
    7. Using a ruler, mark the center line on the pulse wheel teeth on the crank pulley which is located at the 9th tooth counting counterclockwise from the empty space. Refer to the illustration for more detail.
      CAUTION
      If you do not mark the center line correctly this will cause improper engine control for the ignition and fuel system, so be sure to mark the line carefully.

    8.  
    9. Install the CKP sensor making sure the mark on the sensor is aligned with the mark on the pulse wheel. Tighten the sensor bolt to 49-66 inch lbs. (5.5-7.5 Nm)and attach the electrical connector.
    10.  
    11. Remove the tool from the cylinder block lower blind plug.
    12.  
    13. Rotate the crankshaft clockwise 2 turns until you reach TDC. If not aligned properly, loosen the crankshaft pulley lock bolt and reinstall the lock bolt.
    14.  
    15. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).

      Click image to see an enlarged view

      Fig. Using a ruler, mark the center line on the pulse wheel teeth on the crank pulley which is located at the 9th tooth counting counterclockwise from the empty space-2.0L (LF) and 2.3L (L3) engines

    16.  

  12.  
  13. Install the remaining components in the reverse order of removal.
  14.  
  15. Fill the engine with clean oil.
  16.  
  17. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Apply a 0.087-0.126 inch (2.2-3.2mm) bead of sealant around the perimeter of the oil pan-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Use a square ruler to align the oil pan and the block junction side on the engine front cover side-2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Oil pan bolt torque sequence-2.0L (LF) and 2.3L (L3) engines

  18.  

1.5L & 1.8L (BP) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Right-hand splash shield
     
    Transverse member

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components-1.5L engine, 2.0L engine is similar



    Click image to see an enlarged view

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

     
    Oxygen (O 2 S) sensor connector
     
    Exhaust pipe-to-manifold nuts and discard them
     
    Oil pan bolts and the oil pan
     

  6.  

To install:

  1. Clean the oil pan. Clean all dirt, oil, gasket and old sealant from the oil pan and cylinder block contact surfaces.
  2.  
  3. Apply a continuous bead of silicone sealant on the gaskets and around the oil pan, going on the inside of the bolt holes.
  4.  
  5. Install or connect the following:

    New oil pan gaskets
     
    Oil pan. Torque the vertical bolts to 70-95 inch lbs. (8-11 Nm) and the horizontal bolts to 28-38 ft. lbs. (38-51 Nm)
     
    Exhaust pipe. Torque the new nuts to 28-38 ft. lbs. (38-51 Nm)
     
    O 2 S connector
     
    Transverse member. Torque the bolts to 69-97 ft. lbs. (94-131 Nm)
     
    Right-hand splash shield. Torque the bolts to 70-95 inch lbs. (8-11 Nm)
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

1.6L & 1.8L (FP) Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) sensors
     
    Front exhaust pipe
     
    Integrated stiffener (1), for the 1.6L engine
     
    Oil pan, for the 1.8L (FP) engine
     
    Oil pan (2) and oil strainer (3) and the Main Bearing Support Plate (MBSP) (4), for the 1.6L engine
     

  6.  
  7. Clean the oil pan. Clean all dirt, oil, gasket and old sealant from the oil pan and cylinder block contact surfaces.
  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pan and related components-1.6L engine

  1. On the 1.8L (FP) engine, apply a continuous bead of silicone sealant on the gaskets and around the oil pan, going on the inside of the bolt holes.
  2.  
  3. On the 1.6L engine, apply silicone sealant as shown.
  4.  
  5. Install or connect the following:

    New oil pan gasket
     
    Oil pan. Torque the bolts to 14-18 ft. lbs. (19-25 Nm) for the 1.8L engine or to 69.5-95.4 inch lbs. (7.9-10.7 Nm) for the 1.6L engine
     
    Front exhaust pipe
     
    O 2 S
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the vehicle, check for leaks and repair if necessary.
  10.  

1.6L (Zm) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Oxygen (O 2 S) sensors
     
    Front exhaust pipe
     
    Integrated stiffener (1)
     
    Oil pan (2) and oil strainer (3) and the Main Bearing Support Plate (MBSP) (4)
     

  6.  
  7. Clean the oil pan. Clean all dirt, oil, gasket and old sealant from the oil pan and cylinder block contact surfaces.
  8.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the oil pan and related components-1.6L engine



Click image to see an enlarged view

Fig. Apply a bead of silicone sealant to area as illustrated-1.6L (ZM) engines



Click image to see an enlarged view

Fig. Apply a 0.099-0.137 inch (2.5-3.5mm) bead of silicone sealant to the MBSP and along the inside of the bolt holes-1.6L (ZM) engines



Click image to see an enlarged view

Fig. Apply a bead of silicone sealant to new oil pan gaskets-.



Click image to see an enlarged view

Fig. --. and install the gaskets onto the oil pump body and rear cover with the projections in the notches as illustrated-1.6L (ZM) engines



Click image to see an enlarged view

Fig. Apply a 0.079 inch (2mm) bead of silicone sealant to area of the oil pan gaskets marked byA and B-1.6L (ZM) engines



Click image to see an enlarged view

Fig. Location of the integrated stiffener boltA-1.6L (ZM) engines



Click image to see an enlarged view

Fig. Location of the integrated stiffener boltB-1.6L (ZM) engines



Click image to see an enlarged view

Fig. Location of the integrated stiffener boltsC and D-1.6L (ZM) engines

  1. Apply a 0.099-0.137 inch (2.5-3.5mm) bead of silicone sealant to the MBSP and along the inside of the bolt holes.
  2.  
  3. Apply a bead of silicone sealant to new oil pan gaskets. Install the gaskets onto the oil pump body and rear cover with the projections in the notches as illustrated.
  4.  
  5. Apply a 0.079 inch (2mm) bead of silicone sealant to area of the oil pan gaskets marked by A and B in the illustration. Install the gaskets onto the oil pump body and rear cover with the projections in the notches as illustrated.
  6.  
  7. Apply a 0.99-0.137 inch (2.5-3.5mm) bead of silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends.
  8.  
  9. Install or connect the following:

    Oil pan. Torque the bolts to 69.5-95.4 inch lbs. (7.9-10.7 Nm).
     

  10.  
  11. Install the integrated stiffener and hand tighten bolt A , then bolt B .
  12.  
  13. Tighten bolt C to 38 ft. lbs. (52 Nm).
  14.  
  15. Tighten bolt D to 38 ft. lbs. (52 Nm).
  16.  
  17. Tighten bolt A to 38 ft. lbs. (52 Nm).
  18.  
  19. Tighten bolt B to 38 ft. lbs. (52 Nm).

    Front exhaust pipe
     
    O 2 S
     
    Negative battery cable
     

  20.  
  21. Fill the engine with clean oil.
  22.  
  23. Start the vehicle, check for leaks and repair if necessary.
  24.  

1.8L (Bp) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Wheel speed sensor
     
    Dipstick tube
     
    Intermediate shaft
     

  6.  
  7. Attach an engine to the hoist, loosen the oil pan bolts, remove the engine mounting bolts and raise the engine slightly using a hoist.
    CAUTION
    When removing the crossmember, be careful do to damage the brake hoses, A/C pipes and power steering pipes when lowering the crossmember.



    Click image to see an enlarged view

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



    Stabilizer link nut
     
    Shock absorber-to-knuckle nut and bolt
     

  8.  
  9. Support the crossmember with a transmission jack, remove the crossmember retainers. Separate the steering intermediate shaft from the pinion shaft and lower the crossmember until the clearance between the oil pan and the steering gear exceeds 5.12 inch (130mm).
  10.  
  11. Remove or disconnect the following:

    Engine mount
     
    Oil pan bolts and the oil pan using a seal cutter, then insert a flat pry tool into the locations illustrated.

    Click image to see an enlarged view

    Fig. Remove the oil pan by inserting a flat pry tool into the locations shown-1.8L (BP) engine

     

  12.  

To install:

  1. Clean the oil pan. Clean all dirt, oil, gasket and old sealant from the oil pan and cylinder block contact surfaces.
  2.  
  3. Apply a continuous bead of silicone sealant to the contact surfaces of the new oil pan gaskets as illustrated.
  4.  
  5. Install new gaskets into the oil pump body and rear cover facing the notches as illustrated.
  6.  
  7. Apply a 0.079 inch (2mm) continuous bead of silicone sealant on the oil pan as illustrated.
  8.  
  9. Apply a continuous bead of silicone sealant on the oil pan-to-block areas as illustrated.
  10.  
  11. Apply a 0.099-0.137 inch (2.5-3.5mm) continuous bead of silicone sealant on the oil pan along the inside of the bolt holes and overlap the ends.

    Click image to see an enlarged view

    Fig. Apply a continuous bead of silicone sealant to the contact surfaces of the new oil pan gaskets as shown-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Install new gaskets into the oil pump body and rear cover facing the notches as shown-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Apply a 0.079 inch (2mm) continuous bead of silicone sealant on the oil pan as shown-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Apply a continuous bead of silicone sealant on the oil pan-to-block areas as shown-1.8L (BP) engine



    Click image to see an enlarged view

    Fig. Apply a 0.099-0.137 inch (2.5-3.5mm) continuous bead of silicone sealant on the oil pan along the inside of the bolt holes and overlap the ends-1.8L (BP) engine

  12.  
  13. Install or connect the following:

    New oil pan gaskets
     
    Oil pan. Torque the vertical bolts to 70-95 inch lbs. (8-11 Nm) and the horizontal bolts to 48-65 ft. lbs. (64-86 Nm).
     
    Engine mount
     

  14.  
  15. Raise the crossmember into position and tighten the bolts to 15 ft. lbs. (21 Nm) and the nuts to 101 ft lbs. (137 Nm).

    Shock absorber lower nut and bolt and tighten to 86 ft. lbs. (116 Nm)
     
    Stabilizer link nut and tighten to 44 ft. lbs. (60 Nm)
     
    Engine mount nut and tighten to 57 ft. lbs. (78 Nm)
     
    Intermediate shaft and tighten the bolt to 19 ft. lbs. (26 Nm)
     
    Dipstick tube
     
    Wheel speed sensor
     
    Air cleaner assembly
     
    Negative battery cable
     

  16.  
  17. Fill the engine with clean oil.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

1.8L (Fp) Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    oxygen (O2S) sensors
     
    Front exhaust pipe
     
    Oil pan
     

  6.  
  7. Clean the oil pan. Clean all dirt, oil, gasket and old sealant from the oil pan and cylinder block contact surfaces.
  8.  

To install:

  1. Apply a continuous bead of silicone sealant on the gaskets and around the oil pan, going on the inside of the bolt holes.
  2.  
  3. Install or connect the following:

    New oil pan gasket
     
    Oil pan. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    front exhaust pipe
     
    O2S
     
    negative battery cable
     

  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

2.0L (Fs) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components for the 2.0L (FS) engines

     
    Oxygen (O 2 S) sensor
     
    Front exhaust pipe
     
    Oil pan bolts and the oil pan
     

  6.  

To install:

  1. Clean the oil pan. Clean all dirt, oil and old sealant from the oil pan and cylinder block contact surfaces.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pan, going on the inside of the bolt holes.
  4.  
  5. Install or connect the following:

    Oil pan. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).
     
    Front pipe. Torque the nuts to 28-38 ft. lbs. (38-51 Nm).
     
    O 2 S connector
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

2.0L, 2.3L & 2.5L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Passenger side splash shield

    Click image to see an enlarged view

    Fig. Exploded view of the oil pan and related components for the 2.3L and 2.5L engines

     
    Oxygen (O 2 S) sensor
     
    Front exhaust pipe
     
    Oil pan bolts and the oil pan
     

  6.  

To install:

  1. Clean the oil pan. Clean all dirt, oil and old sealant from the oil pan and cylinder block contact surfaces.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pan, going on the inside of the bolt holes.
  4.  
  5. Install or connect the following:

    Oil pan. Torque the bolts to 14-18 ft. lbs. (19-25 Nm)
     
    Front pipe. Torque the nuts to 28-38 ft. lbs. (38-51 Nm)
     
    O 2 S connector
     
    Splash shield. Torque the bolts to 70-95 inch lbs. (8-11 Nm)
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

2.3L (Kj) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Passenger side splash shield
     
    Oxygen (O 2 S) sensor
     
    Front exhaust pipe
     
    Oil pan bolts and the oil pan
     

  6.  

To install:

  1. Clean the oil pan. Clean all dirt, oil and old sealant from the oil pan and cylinder block contact surfaces.
  2.  
  3. Apply a continuous bead of silicone sealant around the oil pan, going on the inside of the bolt holes.
  4.  
  5. Install or connect the following:

    Oil pan. Torque the long bolts to 14-18 ft. lbs. (19-25 Nm) and the short bolts to 70-95 inch lbs. (8-11 Nm).
     
    Front pipe. Torque the nuts to 28-38 ft. lbs. (38-51 Nm).
     
    O 2 S connector
     
    Splash shield
     
    Negative battery cable
     

  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

2.3L (L3) Engine


Click image to see an enlarged view

Fig. Exploded view of the oil pan and related components-Mazda 6 with the 2.3L (L3) engine

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine under cover.
  6.  
  7. Remove the right front wheel.
  8.  
  9. Drain the engine oil.
  10.  
  11. Remove the engine front cover. Refer to the timing chain removal procedure in this section.
  12.  
  13. Remove the dipstick tube pipe and O-ring.
  14.  
  15. Remove the oil pan bolts and use a separator tool to separate the oil pan from the block.
  16.  
  17. Remove the oil pan.
  18.  

To install:

  1. Clean the oil pan mating surfaces.
  2.  
  3. Apply a 0.098 inch (2.5mm) bead of sealant around the perimeter of the oil pan as illustrated.
  4.  
  5. Use a square ruler to align the oil pan and the block junction side on the engine front cover side.
  6.  
  7. Install the oil pan within 5 minutes of applying the sealant.
  8.  
  9. Install the lower oil pan bolts and tighten in sequence to 15-22 ft. lbs. (20-30 Nm) and the oil pan-to-transaxle bolts to 23-38 ft. lbs. (32-52 Nm).
  10.  
  11. Install the remaining components in the reverse order of removal.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.

    Click image to see an enlarged view

    Fig. Apply a 0.098 inch (2.5mm) bead of sealant around the perimeter of the oil pan-Mazda 6 with the 2.3L (L3) engine

  16.  

 
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