Mazda Car 2002-04

Timing Chain 3

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Removal & Installation



3.0L (Aj) Engine
  1. Place the CKP sensor pulse wheel with theFront
  2.  
  3. Apply a 0.24 inch (6mm) bead of silicone sealant to the locations illustrated and install the front cover.
  4.  
  5. Tighten the front cover bolts in the sequence illustrated and tighten the retainers to 15-20 ft. lbs. (20-30 Nm).
  6.  
  7. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as illustrated.
  8.  
  9. Apply clean oil to the seal and push the seal in by hand.
  10.  
  11. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm).
  12.  
  13. Seal the crankshaft pulley using a silicone sealant.
  14.  
  15. Install the pulley using the tools illustrated.
  16.  
  17. While holding the pulley, tighten the crankshaft pulley bolt as follows:

    Tighten to 88 ft. lbs. (120 Nm).
     
    Loosen one full turn.
     
    Tighten to 35-39 ft. lbs. (47-53 Nm).
     
    Tighten 85-95 degrees.
     

  18.  
  19. Install the no. 3 engine mount rubber.
  20.  
  21. When installing the No. 3 engine joint bracket, tighten the No.3 mount bracket bolts and nuts in the order illustrated as follows:

    Bolt 1: 55-77 ft. lbs. (74-105 Nm).
     
    Bolts 2, 3 and 4: 31-44 ft. lbs. (43-60 Nm).
     

  22.  
  23. Install the right hand valve cover.
  24.  
  25. Install the right hand engine hanger.
  26.  
  27. Install the left hand valve cover.
  28.  
  29. Install the dipstick tube.
  30.  
  31. Apply clean engine oil to the camshaft seal and install using the tools illustrated. The seal should be recessed 0.10-0.11 inch (2.5-3mm).
  32.  
  33. Install a new water pump drive belt pulley using tool 49 UN21 1185.
  34.  
  35. Install the water pump drive belt.
  36.  
  37. Install the plug hole plate.
  38.  
  39. Install the remaining components in the reverse order of removal.
  40.  
  41. Chain the engine oil and filter.
  42.  
  43. Check all fluid levels and replenish as necessary.
  44.  
  45. road test the vehicle.
  46.  


    Click image to see an enlarged view

    Fig. Place the CKP sensor pulse wheel with the Front mark facing towards you, using the keyway on the same side as the empty space as shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Apply a 0.24 inch (6mm) bead of silicone sealant to the locations illustrated and install the front cover-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm)-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the pulley using the tools shown-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Tighten the No. 3 engine joint bracket as shown-Mazda 6 models with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the camshaft oil seal-Mazda 6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install a new water pump drive belt pulley using tool 49 UN21 1185-Mazda 6 models with the 3.0L (AJ) engine




Click image to see an enlarged view

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

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the upper intake manifold (dynamic chamber).
  6.  
  7. Remove the ignition coils.
  8.  
  9. Remove the accessory drive belt.
  10.  
  11. Remove the power steering pump and bracket with the lines still attached and set aside.
  12.  
  13. Remove the A/C compressor with the lines still attached and set aside.
  14.  
  15. Unbolt the alternator with the connector still attached and wire it aside.
  16.  
  17. Remove the right hand halfshaft.
  18.  
  19. Remove the front crossmember as follows:
    1. Remove the stabilizer bar nut.
    2.  
    3. Remove the front lower arm front and rear ball joints from the knuckle.
    4.  
    5. Remove the front shock absorber lower bolt.
    6.  
    7. Remove the No. 1 engine mount center bolt.
      WARNING
      Support the crossmember with a suitable jack making sure it is securely damaged or it could fall causing injury or damage.

    8.  
    9. Support the crossmember with a jack and remove the crossmember bracket.
    10.  
    11. Remove the crossmember assembly retainers and lower the jack to remove the crossmember.

      Click image to see an enlarged view

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



      Click image to see an enlarged view

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

    12.  

  20.  
  21. Remove the left hand three way converter.
  22.  
  23. Remove the oil pan.
  24.  
  25. Remove the plug hole plate.
  26.  
  27. Remove the water pump drive belt by rotating the belt tensioner counterclockwise.
  28.  
  29. 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.

      Click image to see an enlarged view

      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

    4.  

  30.  
  31. Cut the camshaft oil seal using a razor knife and remove the seal using the tools illustrated.
  32.  
  33. Remove the oil dipstick tube.
  34.  
  35. Remove the left rocker arm cover.
  36.  
  37. Raise the vehicle and remove the engine hanger bolts and the hanger from below.
  38.  
  39. Remove the right rocker arm cover.

    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

  40.  
  41. 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.

      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

    6.  

  42.  
  43. Remove the No. 3 mount rubber.
  44.  
  45. Remove the A/C compressor and set aside with the lines still attached.
  46.  
  47. Remove the crankshaft pulley using a suitable puller such as the one illustrated.
  48.  
  49. Remove the front oil seal using a prytool as illustrated.

    Click image to see an enlarged view

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



    Click image to see an enlarged view

    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

  50.  
  51. Remove the drive belt tensioner.
  52.  
  53. Remove the engine front cover bolts in the sequence illustrated.
  54.  
  55. Remove the Crankshaft position (CKP) sensor pulse wheel.

    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

  56.  
  57. 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.
      NOTE
      Do not rotate the crankshaft counterclockwise or you may bind the chains causing engine damage.

    2.  
    3. Remove the right side chain in this order:

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

      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



      Click image to see an enlarged view

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

       

    4.  

  58.  
  59. Remove the right side camshaft caps. Refer to the camshaft removal procedure earlier in this section
  60.  
  61. Remove the left side chain tensioner and chain assembly as follows:
    1. Rotate the crankshaft clockwise 1 2 / 3 turns until the keyway is at the 11 O-clock position.
    2.  
    3. Remove the chain in this order:

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

      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

       

    4.  

  62.  
  63. Remove the left side camshaft caps. Refer to the camshaft removal procedure earlier in this section
  64.  

To install:

 
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