Mazda Car 2002-04

Timing Chain 2

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Removal & Installation



3.0L (Aj) Engine


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Fig. Support the crossmember with a jack and remove the crossmember bracket-Mazda 6 with the 3.0L (AJ) engine



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Fig. Exploded view of the crossmember assembly and related components-Mazda 6 with the 3.0L (AJ) engine

  1. Remove the left hand three way converter.
  2.  
  3. Remove the oil pan.
  4.  
  5. Remove the plug hole plate.
  6.  
  7. Remove the water pump drive belt by rotating the belt tensioner counterclockwise.
  8.  
  9. Remove the water pump drive belt pulley as follows:
    1. Replace part of tool 49 UN30 3009 with tool 49 UN30 3457.
    2.  
    3. Install the tools as illustrated and remove the water pump drive pulley.
    4.  

  10.  
  11. Cut the camshaft oil seal using a razor knife and remove the seal using the tools illustrated.
  12.  
  13. Remove the oil dipstick tube.
  14.  
  15. Remove the left rocker arm cover.
  16.  
  17. Raise the vehicle and remove the engine hanger bolts and the hanger from below.
  18.  
  19. Remove the right rocker arm cover.
  20.  
  21. Remove the No. 3 joint bracket as follows:
    1. Install the right hand engine hanger.
    2.  
    3. Use a M10 x 1.25 0.984 (25mm) length bolt to attach tool 49 UN30 3050 as illustrated. Tighten the bolt to 73-92 ft. lbs. (100-125 Nm).
    4.  
    5. Suspend the engine using the engine support device and remove the joint bracket.
    6.  

  22.  
  23. Remove the No. 3 mount rubber.
  24.  
  25. Remove the A/C compressor and set aside with the lines still attached.
  26.  
  27. Remove the crankshaft pulley using a suitable puller such as the one illustrated.
  28.  
  29. Remove the front oil seal using a prytool as illustrated.
  30.  
  31. Remove the drive belt tensioner.
  32.  
  33. Remove the engine front cover bolts in the sequence illustrated.
  34.  
  35. Remove the Crankshaft position (CKP) sensor pulse wheel.
  36.  
  37. Remove the right side chain tensioner and chain assembly as follows:
    1. Rotate the crankshaft clockwise so the crankshaft keyway is at the 3 O-clock position. The camshafts should be in the neutral position.
    2.  

  38.  


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    Fig. Exploded view of the water pump and related components-Mazda 6 models with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Replace part of tool 49 UN30 3009 with tool 49 UN30 3457-Mazda 6 models with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the tools as illustrated and remove the water pump drive pulley-Mazda 6 models with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Cut the camshaft oil seal using a razor knife and remove the seal as shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Use a M10 x 1.25 0.984 (25mm) length bolt to attach tool 49 UN30 3050 as shown-Mazda 6 with the 3.0L (AJ) engine



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    Fig. Hold the crankshaft pulley using the tools illustrated and remove the pulley bolt-Mazda 6 with the 3.0L (AJ) engine



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    Fig. Remove the crankshaft pulley using a suitable puller such as the one shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Remove the front oil seal using a prytool as shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Remove the engine front cover bolts in the sequence shown-Mazda 6 with the 3.0L (AJ) engine



NOTE
Do not rotate the crankshaft counterclockwise or you may bind the chains causing engine damage.

  1. Remove the right side chain in this order:
  2.  
  3. Chain tensioner
  4.  
  5. Tensioner arm
  6.  
  7. Timing chain
  8.  
  9. Chain guide
  10.  
  11. Timing chain crankshaft sprocket
  12.  



Click image to see an enlarged view

Fig. Rotate the crankshaft clockwise so the crankshaft keyway is at the 3 O-clock position when removing the right side chain-Mazda 6 with the 3.0L (AJ) engine



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Fig. Remove right side timing chain in numerical order-Mazda 6 with the 3.0L (AJ) engine



Remove the right side camshaft caps. Refer to the camshaft removal procedure earlier in this section
 
Remove the left side chain tensioner and chain assembly as follows:
  1. Rotate the crankshaft clockwise 123
  2.  
  3. Remove the chain in this order:
  4.  
  5. Chain tensioner
  6.  
  7. Tensioner arm
  8.  
  9. Timing chain
  10.  
  11. Chain guide
  12.  
  13. Timing chain crankshaft sprocket
  14.  

 
Remove the left side camshaft caps. Refer to the camshaft removal procedure earlier in this section
 


Click image to see an enlarged view

Fig. Rotate the crankshaft clockwise 12/3turns until the keyway is at the 11 O-clock when removing the left side chain-Mazda 6 with the 3.0L (AJ) engine



Click image to see an enlarged view

Fig. Remove left side timing chain in numerical order-Mazda 6 with the 3.0L (AJ) engine


To install:

  1. Install the left side chain assembly as follows:

    Make sure the crankshaft keyway is at the 11 O-clock position.
     
    Position the mark on the intake camshaft to 9 O-clock.
     
    Place the mark on the exhaust camshaft at the 12 O-clock position.
     


    Click image to see an enlarged view

    Fig. When installing the left side chain, make sure the crankshaft keyway is at the 11 O-clock position-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. When installing the left side chain, Position the mark on the intake camshaft to 9 O-clock and the mark on the exhaust camshaft at the 12 O-clock position-Mazda 6 with the 3.0L (AJ) engine

    Align the colored links on the timing chain with the marks on the timing sprockets.
     
    If the timing chain marks cannot be seen, use a marker or paint pen to mark the crankshaft and camshaft marks on the chain as follows:
     
    Mark any link as the crankshaft link
     
    Count 29 links from the crankshaft mark and place a mark to be used as the exhaust camshaft sprocket mark
     
    Continue counting to the 42 link mark and mark this link as the intake camshaft sprocket mark
     

  2.  
  3. Install the left hand chain in this order:
    1. Timing chain crankshaft sprocket
    2.  
    3. Chain guide
    4.  
    5. Timing chain
    6.  
    7. Tensioner arm
    8.  
    9. Chain tensioner
    10.  

  4.  


NOTE
The chain guide should be installed to the actuator and allowed to hang freely when the bolts are installed. Do not hold the guide up when installing the bolts. The actuator causes wear to an O-ring and holding the guide will increase wear.

  1. Install the left side camshaft caps. Refer to the camshaft removal procedure earlier in this section
  2.  


    Click image to see an enlarged view

    Fig. If the timing chain marks cannot be seen, use a marker or paint pen to mark the crankshaft and camshaft marks on the chain. Refer to the text for marking steps.-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the left side timing chain in numerical order and align the colored links with the timing marks on the sprockets-Mazda 6 with the 3.0L (AJ) engine

  3. Install the left side chain tensioner as follows:
  4.  
  5. Place the tensioner in a vise with jaw protectors
  6.  
  7. Use a small screwdriver to hold the tensioner ratchet lock mechanism away from the ratchet stem
  8.  


NOTE
Minimal force should be used to retract the piston, if binding occurs remove then reinstall the tensioner in the vise.



Slowly compress the tensioner piston and install a paper clip to hold the piston
 
Install the tensioner, tighten the bolts to 15-22 ft. lbs. (20-30 Nm) and remove the paper clip
 



Install the right side chain assembly as follows:
  1. Make sure the crankshaft keyway is at the 3 O-clock position.
  2.  
  3. Place the mark on the exhaust camshaft at the 12 O-clock position.
  4.  
  5. Position the mark on the intake camshaft to 3 O-clock.
  6.  


    Click image to see an enlarged view

    Fig. When installing the right side chain, make sure the crankshaft keyway is at the 3 O-clock position-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. When installing the right side chain, Position the mark on the exhaust camshaft to 12 O-clock and the mark on the intake camshaft at the 3 O-clock position-Mazda 6 with the 3.0L (AJ) engine

  7. Align the colored links on the timing chain with the marks on the timing sprockets.
  8.  
  9. If the timing chain marks cannot be seen, use a marker or paint pen to mark the crankshaft and camshaft marks on the chain as follows:
  10.  
  11. Mark any link as the crankshaft link
  12.  
  13. Count 29 links from the crankshaft mark and place a mark to be used as the exhaust camshaft sprocket mark
  14.  
  15. Continue counting to the 42 link mark and mark this link as the intake camshaft sprocket mark
  16.  

 
Install the left hand chain in this order:

Timing chain crankshaft sprocket
 
Chain guide
 
Timing chain
 
Tensioner arm
 
Chain tensioner
 

 


NOTE
The chain guide should be installed to the actuator and allowed to hang freely when the bolts are installed. Do not hold the guide up when installing the bolts. The actuator causes wear to an O-ring and holding the guide will increase wear.



Install the right side camshaft caps. Refer to the camshaft removal procedure earlier in this section
 


Click image to see an enlarged view

Fig. Install the right side timing chain in numerical order and align the colored links with the timing marks on the sprockets-Mazda 6 with the 3.0L (AJ) engine

Install the right side chain tensioner as follows:
 
Place the tensioner in a vise with jaw protectors
 
Use a small screwdriver to hold the tensioner ratchet lock mechanism away from the ratchet stem
 


NOTE
Minimal force should be used to retract the piston, if binding occurs remove then reinstall the tensioner is the vise.

  1. Slowly compress the tensioner piston and install a paper clip to hold the piston
  2.  
  3. Install the tensioner, tighten the bolts to 15-22 ft. lbs. (20-30 Nm) and remove the paper clip.
  4.  

 
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