Mazda Car 2002-04

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



2.3L (L3) Engine


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Fig. Exploded view of the timing chain assembly 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 cylinder head cover.
  6.  
  7. Remove the cylinder block lower blind plug.
  8.  
  9. Install tool 49 JE01 061.
  10.  
  11. 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).
  12.  
  13. Hold the crankshaft pulley using the tools illustrated and remove the bolt.
  14.  
  15. Remove the crankshaft pulley.
  16.  
  17. Remove the water pump pulley.
  18.  
  19. Remove the drive belt idler pulley.
  20.  
  21. Install an engine support device such as 49 E017 5A0.
  22.  
  23. Remove the No. 3 engine mount and joint.
  24.  
  25. Remove the engine front cover and oil seal.
  26.  
  27. Unlock the chain tensioner using a suitable tool to slowly compress the tensioner piston. Insert a 0.059 inch (1.5mm) wire or a paper clip to hold the piston in its compressed position.
  28.  
  29. Remove the tensioner arm, chain guide and timing chain.
  30.  


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    Fig. Install tool 49 JE01 061-Mazda 6 with the 2.3L (L3) engine



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    Fig. Install tools 205-072-02 and 205-126 to hold the crankshaft pulley using the tools illustrated and remove the bolt-Mazda 6 with the 2.3L (L3) engine



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    Fig. Compressing and retaining the chain tensioner piston - Mazda 6 with the 2.3L (L3) engine


To install:



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Fig. Install tool 49 UN30 3465 on the camshaft-Mazda 6 with the 2.3L (L3) engine

  1. Install tool 49 UN30 3465 as illustrated on the camshaft.
  2.  
  3. Install the timing chain and remove the paper clip or wire retaining the tensioner piston to apply tension to the chain.
  4.  
  5. Install the timing chain guide and tighten the bolts to 71-101 inch lbs. (8-11.5 Nm).
  6.  
  7. Install the tensioner arm and tighten the bolts to 71-101 inch lbs. (8-11.5 Nm).
  8.  
  9. Install a new oil seal in the front cover as follows:
    1. Coat the new seal with clean engine oil.
    2.  
    3. Push the seal in by hand to get it started.
    4.  
    5. Use seal installer tool 49 H010 401 and a hammer to install the seal so that it is recessed 0-0.019 inch (0-0.5mm) as shown in the accompanying illustration.
    6.  



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    Fig. Use seal installer tool 49 H010 401 and a hammer to install the seal-Mazda 6 with the 2.3L (L3) engine



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    Fig. The seal should be recessed 0-0.019 inch (0-0.5mm) as shown when properly installed-Mazda 6 with the 2.3L (L3) engine

  10.  
  11. Apply sealant to the engine front cover. At point A the bead should be 0.087-0.125 inch (2.2-3.2mm) thick and at point B the bead should be 0.059-0.098 inch (1.5-2.5mm) thick. Refer to the accompanying illustration for the locations of points A and B.
  12.  
  13. Install the cover within 10 minutes of apply the sealant. Tighten the cover bolts as follows:
    1. Bolts 1 through 18: In sequence to 71-101 inch lbs. (8-11.5 Nm).
    2.  
    3. Bolts 19 through 22 : In sequence to 29.7-40.5 ft. lbs. (40-55 Nm).
    4.  
    5. Bolt 23 : 14.8-22 ft. lbs. (20-30 Nm).
    6.  

  14.  
  15. When installing the No. 3 engine joint bracket, tighten the mount bracket stud bolt to 62-115 inch lbs. (7-13 Nm) and the joint bracket bolt and nut in the order illustrated to 55-76 ft. lbs. (74-105 Nm).
  16.  
  17. Install the drive belt idler and water pump pulleys.
  18.  
  19. Install tool 49 UN30 3465 as illustrated on the camshaft.
  20.  
  21. Install and hand tighten the M6 x 1.0 bolt as illustrated.
  22.  
  23. Turn the crankshaft clockwise until the crankshaft is in number 1 TDC (the balance weight should be attached to the tool).
  24.  
  25. Hold the crankshaft pulley and tighten the lock bolt in two steps. First tighten to 71-77 ft. lbs. (96-104 Nm). Then final tighten an additional 87-93 degrees.
  26.  
  27. Remove the M6 x 1.0 bolt.
  28.  
  29. Remove the tools from the camshaft and the cylinder block lower blind plug.
  30.  
  31. 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 again using the above procedure and special tools.
  32.  
  33. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  34.  
  35. Install the cylinder head cover with a new gasket. Torque the bolts in the sequence illustrated to 71-93 inch lbs. (8-11 Nm).
  36.  
  37. Install the remaining components in the reverse order of removal.
  38.  
  39. Change the engine oil.
  40.  
  41. Start the engine.
  42.  
  43. Inspect for the following:

    Pulley and belt for run-out and contact
     
    Any leaking fluids.
     
    Ignition timing, idle speed and exhaust emissions
     
    All remaining components for proper operation.
     

  44.  


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    Fig. Apply a bead of sealant to the engine front cover at the locations shown. Refer to the text for the bead thickness-Mazda 6 with the 2.3L (L3) engine



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    Fig. Engine front cover bolts tightening sequence-Mazda 6 with the 2.3L (L3) engine



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    Fig. No. 3 engine mount bracket stud bolt locations-Mazda 6 models with the 2.3L (L3) engine



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    Fig. Tighten the No. 3 joint bracket bolts and nuts in the order shown-Mazda 6 models with the 2.3L (L3) engine



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    Fig. Install and hand tighten the M6 x 1.0 bolt-Mazda 6 with the 2.3L (L3) engine


 
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