Mazda Car 2002-04

Timing Chain 4

Print

Removal & Installation



3.0L (Aj) Engine
  1. Install the left side chain assembly as follows:
    1. Make sure the crankshaft keyway is at the 11 O-clock position.
    2.  
    3. Position the mark on the intake camshaft to 9 O-clock.
    4.  
    5. 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

    6.  
    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:

      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
       

    10.  

  2.  
  3. Install the left hand chain in this order:
    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.



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

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

      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

    2.  
    3. Install the left side chain tensioner as follows:
      NOTE
      Minimal force should be used to retract the piston, if binding occurs, remove then reinstall the tensioner in the vise.



      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
       



      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
       

    4.  

  4.  
  5. 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.

      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

    6.  
    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:

      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
       

    10.  

  6.  
  7. Install the left hand chain in this order:
    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.



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

    1. 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

    2.  
    3. Install the right side chain tensioner as follows:
      NOTE
      Minimal force should be used to retract the piston, if binding occurs, remove then reinstall the tensioner is the vise.



      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
       



      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.
       

    4.  

  8.  
  9. 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 illustrated.

    Click image to see an enlarged view

    Fig. Place the CKP sensor pulse wheel with theFrontmark 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

  10.  
  11. Apply a 0.24 inch (6mm) bead of silicone sealant to the locations illustrated and install the front cover.
  12.  
  13. Tighten the front cover bolts in the sequence illustrated and tighten the retainers to 15-20 ft. lbs. (20-30 Nm).
  14.  
  15. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as illustrated.
  16.  
  17. Apply clean oil to the seal and push the seal in by hand.
  18.  
  19. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm).
  20.  
  21. Seal the crankshaft pulley using a silicone sealant.

    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

  22.  
  23. Install the pulley using the tools illustrated.
  24.  
  25. While holding the pulley, tighten the crankshaft pulley bolt as follows:
    1. Tighten to 88 ft. lbs. (120 Nm).
    2.  
    3. Loosen one full turn.
    4.  
    5. Tighten to 35-39 ft. lbs. (47-53 Nm).
    6.  
    7. Tighten 85-95 degrees.
    8.  

  26.  
  27. Install the no. 3 engine mount rubber.
  28.  
  29. When installing the No. 3 engine joint bracket, tighten the No. 3 mount bracket bolts and nuts in the order illustrated as follows:
    1. Bolt 1: 55-77 ft. lbs. (74-105 Nm).
    2.  
    3. Bolts 2, 3 and 4: 31-44 ft. lbs. (43-60 Nm).

      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

    4.  

  30.  
  31. Install the right hand valve cover.
  32.  
  33. Install the right hand engine hanger.
  34.  
  35. Install the left hand valve cover.
  36.  
  37. Install the dipstick tube.
  38.  
  39. 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).

    Click image to see an enlarged view

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

  40.  
  41. Install a new water pump drive belt pulley using tool 49 UN21 1185.
  42.  
  43. Install the water pump drive belt.
  44.  
  45. Install the plug hole plate.
  46.  
  47. Install the remaining components in the reverse order of removal.
  48.  
  49. Chain the engine oil and filter.
  50.  
  51. Check all fluid levels and replenish as necessary.
  52.  
  53. Road test the vehicle.

    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

  54.  

 
label.common.footer.alt.autozoneLogo