Mazda Car 2002-04

Timing Chain & Sprockets 2

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Removal & Installation



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-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Remove the front oil seal using a prytool as shown-Mazda6 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-Mazda6 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
      &n