Mazda Car 2002-04

Timing Chain & Sprockets 1

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Removal & Installation



2.0L (Lf) And 2.3L (L3) Engines


Click image to see an enlarged view

Fig. Exploded view of the timing chain assembly and related components-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the plug hole plate and bracket.
  4.  
  5. Remove the accelerator cable and bracket.
  6.  
  7. Remove the battery cover and disconnect the negative battery cover.
  8.  
  9. Remove the ignition coils.
  10.  
  11. Remove the right hand front wheel.
  12.  
  13. Remove the engine under cover and splash shields.
  14.  
  15. Remove the Crankshaft Position (CKP) sensor.
  16.  
  17. Remove the accessory drive belt.
  18.  
  19. Remove the A/C compressor and set aside with the lines attached.
  20.  
  21. Remove the coolant reservoir tank and set aside with the lines still attached.
  22.  
  23. Remove the cylinder head cover.
  24.  
  25. Remove the cylinder block lower blind plug.
  26.  
  27. Install tool 49 JE01 061.
  28.  
  29. 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).
  30.  
  31. Hold the crankshaft pulley using the tools illustrated and remove the bolt.
  32.  
  33. Remove the crankshaft pulley.

    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061 to hold the crankshaft pulley using the tools illustrated and remove the bolt-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

  34.  
  35. Remove the water pump pulley.
  36.  
  37. Remove the drive belt tensioner.
  38.  
  39. Remove the No. 3 engine mount and joint bracket as follows:
    1. Install two suitable pieces of wood between the front fender panel and upper apron reinforcement as illustrated. The wood size should be approximately 1.38 inch (35mm) on 4 door models or 2.36 inch (60mm) on 5 door models.
    2.  

  40.  
  41. Install an engine support device such as 49 E017 5A0.

    Click image to see an enlarged view

    Fig. Install two suitable pieces of wood between the front fender panel and upper apron reinforcement-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

  42.  
  43. Remove the engine front cover and oil seal.
  44.  
  45. 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.

    Click image to see an enlarged view

    Fig. Compressing and retaining the chain tensioner piston-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

  46.  
  47. Remove the tensioner arm, chain guide and timing chain.
  48.  

To install:

Click image to see an enlarged view

Fig. Install tool 49 UN30 3465 on the camshaft-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

  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:

    Click image to see an enlarged view

    Fig. Use seal installer tool 49 H010 401 and a hammer to install the seal-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. The seal should be recessed 0-0.019 inch (0-0.5mm) as shown when properly installed-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

    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.  

  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. No sealant is needed at the points marked C on 2.3L (L3) engines with variable valve timing.
  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).

      Click image to see an enlarged view

      Fig. Apply a bead of sealant to the engine front cover at the locations shown. Refer to the text for the bead thickness-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines



      Click image to see an enlarged view

      Fig. Engine front cover bolts tightening sequence-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines



      Click image to see an enlarged view

      Fig. Location of the No. 3 engine mount bracket stud bolts-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

    6.  

  14.  
  15. Install the No. 3 engine mount and joint bracket as follows:
    1. Tighten the No. 3 mount bracket stud bolts to 62-115 inch lbs. (7-13 Nm). Tighten the stud bolt with the mount nut loosened.
    2.  
    3. Hand tighten the mount rubber and bracket nuts and bolts, then tighten in the sequence illustrated to 55-77 ft. lbs. (74-105 Nm).

      Click image to see an enlarged view

      Fig. Tighten the mount rubber and bracket nuts and bolts in the sequence-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines



      Click image to see an enlarged view

      Fig. Install and hand tighten the M6 x 1.0 bolt-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

    4.  

  16.  
  17. Install tool 49 UN30 3465 as illustrated on the camshaft.
  18.  
  19. Install and hand tighten the M6 x 1.0 bolt as illustrated.
  20.  
  21. Turn the crankshaft clockwise until the crankshaft is in number 1 TDC (the balance weight should be attached to the tool).
  22.  
  23. 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.
  24.  
  25. Remove the M6 x 1.0 bolt.
  26.  
  27. Remove the tools from the camshaft and the cylinder block lower blind plug.
  28.  
  29. 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.
  30.  
  31. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  32.  
  33. Apply a 0.16-0.24 inch (4-7mm) bead of silicone sealant to cylinder head at the areas illustrated. Make sure to install the cover within 10 minutes of applying the sealant.
  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).

    Click image to see an enlarged view

    Fig. Apply silicone sealant to cylinder head at the areas illustrated-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Tighten the cylinder head cover bolts in the sequence shown-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

  36.  
  37. Install the remaining components in the reverse order of removal.
  38.  
  39. 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-Mazda3 with the 2.0L (LF) and 2.3L (L3) engines

    16.  

  40.  
  41. Change the engine oil.
  42.  
  43. Start the engine.
  44.  
  45. 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.
     

  46.  

2.3L (L3) Engine


Click image to see an enlarged view

Fig. Exploded view of the timing chain assembly and related components-Mazda6 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.

    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061-Mazda6 with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Install tools 205-072-02 and 205-126 to hold the crankshaft pulley using the tools illustrated and remove the bolt-Mazda6 with the 2.3L (L3) engine

  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.

    Click image to see an enlarged view

    Fig. Compressing and retaining the chain tensioner piston-Mazda6 with the 2.3L (L3) engine

  28.  
  29. Remove the tensioner arm, chain guide and timing chain.
  30.  

To install:

Click image to see an enlarged view

Fig. Install tool 49 UN30 3465 on the camshaft-Mazda6 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:

    Click image to see an enlarged view

    Fig. Use seal installer tool 49 H010 401 and a hammer to install the seal-Mazda6 with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. The seal should be recessed 0-0.019 inch (0-0.5mm) as shown when properly installed-Mazda6 with the 2.3L (L3) engine

    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.  

  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).

      Click image to see an enlarged view

      Fig. Apply a bead of sealant to the engine front cover at the locations shown. Refer to the text for the bead thickness-Mazda6 with the 2.3L (L3) engine



      Click image to see an enlarged view

      Fig. Engine front cover bolts tightening sequence-Mazda6 with the 2.3L (L3) engine

    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).

    Click image to see an enlarged view

    Fig. No. 3 engine mount bracket stud bolt locations-Mazda6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Tighten the No. 3 joint bracket bolts and nuts in the order shown-Mazda6 models with the 2.3L (L3) engine

  16.  
  17. Install the drive belt idler and water pump pulleys.

    Click image to see an enlarged view

    Fig. Install and hand tighten the M6 x 1.0 bolt-Mazda6 with the 2.3L (L3) engine

  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.  

3.0L (Aj) Engine


Click image to see an enlarged view

Fig. Exploded view of the timing chain assembly and related components-Mazda6 with the 3.0L (AJ) engine

 
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