Mazda Car 2002-04

Valve Lash (Clearance) Adjustment 1

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These engines use solid cam followers with a removable adjustment shim. The valve lash clearance is measured with the original shim installed and checked against the specification. If adjustment is necessary, the original shim is removed, and a thicker or thinner shim is installed to obtain the proper clearance. Special tools are required in order to adjust the shim without removing the camshaft.

These engines use solid cam followers with a removable adjustment shim. The valve lash clearance is measured with the original shim installed and checked against the specification. If adjustment is necessary, the original shim is removed, and a thicker or thinner shim is installed to obtain the proper clearance. Special tools are required in order to adjust the shim without removing the camshaft.

These engines use solid cam followers with a removable adjustment shim. The valve lash clearance is measured with the original shim installed and checked against the specification. If adjustment is necessary, the original shim is removed, and a thicker or thinner shim is installed to obtain the proper clearance. Special tools are required in order to adjust the shim without removing the camshaft.

These engines use solid cam followers with a removable adjustment shim. The valve lash clearance is measured with the original shim installed and checked against the specification. If adjustment is necessary, the original shim is removed, and a thicker or thinner shim is installed to obtain the proper clearance. Special tools are required in order to adjust the shim without removing the camshaft.

1.6L (Zm) & 1.8 (Fp) Engines




NOTE
With the engine cold, standard valve clearance is 0.010-0.012 inch (0.25-0.31mm) on 1.6L (ZM) engines or 0.010-0.001 inch (0.225-0.295mm) on 1.8L (FP) engines on both the intake and exhaust sides.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the cylinder head cover.
  4.  
  5. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  6.  
  7. Measure the valve clearance atA
  8.  
  9. Turn the crankshaft clockwise 360 degrees until the No. 4 piston is at TDC. Measure the valve clearance atB
  10.  
  11. Repeat this procedure for all the camshafts.
  12.  
  13. Turn the crankshaft clockwise until the cam on the camshaft requiring the adjustment is positioned straight up.
  14.  
  15. Remove the camshaft cap bolts as follows:
    1. For exhaust side No. 1, 2 and 3 cylinder adjustment shim removal useA
    2.  
    3. For intake side No. 1, 2 and 3 cylinder adjustment shim removal useB
    4.  
    5. For exhaust side No. 2, 3 and 4 cylinder adjustment shim removal useC
    6.  
    7. For intake side No. 2, 3 and 4 cylinder adjustment shim removal useD
    8.  

  16.  
  17. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes. Tighten the bolts to 100-125 inch lbs. (11-14 Nm).
  18.  
  19. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp). Tighten special tool 49-T012-004 (bolt) to secure the shaft.
  20.  
  21. Position special tool 49-T012-001A toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement.
  22.  
  23. Position the notch of the tappet to allow a small prytool to be inserted.
  24.  
  25. Set the special tool on the tappet by its notch. Tighten the mounting boltB
  26.  
  27. Tighten boltC
  28.  
  29. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet. Remove the shim with a magnet.
  30.  
  31. Select and install the proper adjustment shim. Loosen boltCB
  32.  
  33. Remove special tools 49-T012-002, 003 and 004, and torque the camshaft cap bolts to 100-125 inch lbs. (11-14 Nm).
  34.  
  35. Repeat the procedure for all necessary adjustment shims. Check the valve clearance.
  36.  


    Click image to see an enlarged view

    Fig. Valve clearance checking positions-4-cylinder engines



    Click image to see an enlarged view

    Fig. Cam bearing cap bolt removal positions-4-cylinder engine



    Click image to see an enlarged view

    Fig. Mount the tappet depressor tool onto the shaft above the tappet that needs adjustment



    Click image to see an enlarged view

    Fig. With the tappet depressed, use a small prytool to remove the adjustment shim


1.6L (Zm) Engines




NOTE
With the engine cold, standard valve clearance is 0.010-0.012 inch (0.25-0.31mm) on both the intake and exhaust sides.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the cylinder head cover.
  4.  
  5. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  6.  
  7. Measure the valve clearance at A . If the clearance exceeds specifications, replace the adjustment shim.

    Click image to see an enlarged view

    Fig. Valve clearance checking positions-4-cylinder engines

  8.  
  9. Turn the crankshaft clockwise 360 degrees until the No. 4 piston is at TDC. Measure the valve clearance at B . If the clearance exceeds specifications, replace the adjustment shim.
  10.  
  11. Repeat this procedure for all the camshafts.
  12.  
  13. Turn the crankshaft clockwise until the cam on the camshaft requiring the adjustment is positioned straight up.

    Click image to see an enlarged view

    Fig. Cam bearing cap bolt removal positions-4-cylinder engine

  14.  
  15. Remove the camshaft cap bolts as follows:
    1. For exhaust side No. 1, 2 and 3 cylinder adjustment shim removal use A .
    2.  
    3. For intake side No. 1, 2 and 3 cylinder adjustment shim removal use B .
    4.  
    5. For exhaust side No. 2, 3 and 4 cylinder adjustment shim removal use C .
    6.  
    7. For intake side No. 2, 3 and 4 cylinder adjustment shim removal use D .
    8.  

  16.  
  17. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes. Tighten the bolts to 100-125 inch lbs. (11-14 Nm).
  18.  
  19. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp). Tighten special tool 49-T012-004 (bolt) to secure the shaft.
  20.  
  21. Position special tool 49-T012-001A toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement.
  22.  
  23. Position the notch of the tappet to allow a small prytool to be inserted.

    Click image to see an enlarged view

    Fig. Mount the tappet depressor tool onto the shaft above the tappet that needs adjustment



    Click image to see an enlarged view

    Fig. With the tappet depressed, use a small prytool to remove the adjustment shim

  24.  
  25. Set the special tool on the tappet by its notch. Tighten the mounting bolt B securing it on the shaft.
  26.  
  27. Tighten bolt C , and press down the tappet.
  28.  
  29. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet. Remove the shim with a magnet.
  30.  
  31. Select and install the proper adjustment shim. Loosen bolt C to allow the tappet to move up, and loosen bolt B to remove special tool 49-T012-001A.
  32.  
  33. Remove special tools 49-T012-002, 003 and 004, and torque the camshaft cap bolts to 100-125 inch lbs. (11-14 Nm).
  34.  
  35. Repeat the procedure for all necessary adjustment shims. Check the valve clearance.
  36.  

1.8L Engine




NOTE
With the engine cold, standard valve clearance is 0.08-0.009 inch (0.18-0.24mm) on intake side and 0.012-0.013 inch (0.28-0.34mm) on the exhaust side.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the cylinder head cover.
  4.  
  5. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  6.  
  7. Measure the valve clearance at A . If the clearance exceeds specifications, replace the adjustment shim.

    Click image to see an enlarged view

    Fig. Valve clearance checking positions-1.8L (BP) engines

  8.  
  9. Turn the crankshaft clockwise until the cam on the camshaft requiring the adjustment is positioned straight up.
  10.  
  11. Turn the crankshaft clockwise 360 degrees until the No. 4 piston is at TDC. Measure the valve clearance at B . If the clearance exceeds specifications, replace the adjustment shim.
  12.  
  13. Repeat this procedure for all the camshafts.
  14.  
  15. Turn the crankshaft clockwise until the cam on the camshaft requiring the adjustment is positioned straight up.

    Click image to see an enlarged view

    Fig. Cam bearing cap bolt removal positions-1.8L (BP) engines

  16.  
  17. Remove the camshaft cap bolts one pair at a time as follows:
    1. For exhaust side No. 1, 2 and 3 cylinder adjustment shim removal use A .
    2.  
    3. For intake side No. 1, 2 and 3 cylinder adjustment shim removal use B .
    4.  
    5. For exhaust side No. 2, 3 and 4 cylinder adjustment shim removal use C .
    6.  
    7. For intake side No. 2, 3 and 4 cylinder adjustment shim removal use D .
      NOTE
      For exhaust side No-s. 2 and 3, cylinder adjustment shim removal; remove bolts A or C . For intake side No-s 2 and 3 cylinder adjustment shim removal, remove bolts B or B .

    8.  

  18.  
  19. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes. Tighten the bolts to 100-125 inch lbs. (11-14 Nm).
  20.  
  21. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp). Tighten special tool 49-T012-004 (bolt) to secure the shaft.
  22.  
  23. Position special tool 49-T012-001A toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement.
  24.  
  25. Position the notch of the tappet to allow a small prytool to be inserted.

    Click image to see an enlarged view

    Fig. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Position special tool 49-T012-001A toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Tighten the mounting boltBsecuring it on the shaft. Tighten boltCand press down the tappet-1.8L (BP) engines



    Click image to see an enlarged view

    Fig. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet-1.8L (BP) engines

  26.  
  27. Set the special tool on the tappet by its notch. Tighten the mounting bolt B securing it on the shaft.
  28.  
  29. Tighten bolt C , and press down the tappet.
  30.  
  31. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet. Remove the shim with a magnet.
  32.  
  33. Select and install the proper adjustment shim. Loosen bolt C to allow the tappet to move up, and loosen bolt B to remove special tool 49-T012-001A.
  34.  
  35. Remove special tools 49-T012-002, 003 and 004, and torque the camshaft cap bolts to 100-125 inch lbs. (11-14 Nm).
  36.  
  37. Repeat the procedure for all necessary adjustment shims. Check the valve clearance.
  38.  

2.0L (Fs) Engine




NOTE
With the engine cold, standard valve clearance is 0.0089-0.0116 inch (0.225-0.295mm) on intake and exhaust sides.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the cylinder head cover.
  4.  
  5. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).

    Click image to see an enlarged view

    Fig. Ensure that the cam lobe faces away from the follower when checking the valve clearance

  6.  
  7. Measure the valve clearance at A . If the clearance exceeds specifications, replace the adjustment shim.

    Click image to see an enlarged view

    Fig. Valve clearance checking positions-2.0L (FS) engines

  8.  
  9. Turn the crankshaft clockwise 360 degrees until the No. 4 piston is at TDC. Measure the valve clearance at B . If the clearance exceeds specifications, replace the adjustment shim.
  10.  
  11. Repeat this procedure for all the camshafts.
  12.  
  13. Turn the crankshaft clockwise until the cam on the camshaft requiring the adjustment is positioned straight up.

    Click image to see an enlarged view

    Fig. Cam bearing cap bolt removal positions-2.0L (FS) engines

  14.  
  15. Remove the camshaft cap bolts as follows:
    1. For exhaust side No. 1, 2 and 3 cylinder adjustment shim removal use A .
    2.  
    3. For intake side No. 1, 2 and 3 cylinder adjustment shim removal use B .
    4.  
    5. For exhaust side No. 2, 3 and 4 cylinder adjustment shim removal use C .
    6.  
    7. For intake side No. 2, 3 and 4 cylinder adjustment shim removal use D .
    8.  

  16.  
  17. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes. Tighten the bolts to 100-125 inch lbs. (11-14 Nm).
  18.  
  19. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp). Tighten special tool 49-T012-004 (bolt) to secure the shaft.
  20.  
  21. Position special tool 49-T012-001A toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement.
  22.  
  23. Position the notch of the tappet to allow a small prytool to be inserted.

    Click image to see an enlarged view

    Fig. Mount the tappet depressor tool onto the shaft above the tappet that needs adjustment-2.0L (FS) engines



    Click image to see an enlarged view

    Fig. With the tappet depressed, use a small prytool to remove the adjustment shim-2.0L (FS) engines

  24.  
  25. Set the special tool on the tappet by its notch. Tighten the mounting bolt B securing it on the shaft.
  26.  
  27. Tighten bolt C , and press down the tappet.
  28.  
  29. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet. Remove the shim with a magnet.
  30.  
  31. Select and install the proper adjustment shim. Loosen bolt C to allow the tappet to move up, and loosen bolt B to remove special tool 49-T012-001A.
  32.  
  33. Remove special tools 49-T012-002, 003 and 004, and torque the camshaft cap bolts to 100-125 inch lbs. (11-14 Nm).
  34.  
  35. Repeat the procedure for all necessary adjustment shims. Check the valve clearance.
  36.  

2.0L (Lf) Engine




NOTE
With the engine cold, standard valve clearance is 0.0087-0.0110 inch (0.22-0.28mm) on the intake side and 0.0107-0.0129 inch (0.27-0.33mm) on the exhaust side.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the plug hole plate.
  4.  
  5. Remove the battery cover and disconnect the negative battery cable.
  6.  
  7. Disconnect the wiring harness.
  8.  
  9. Remove the right front wheel, engine under cover and splash shield.
  10.  
  11. Remove the ignition coils.
  12.  
  13. Remove the Positive Crankcase Ventilation (PCV) hose, if equipped.
  14.  
  15. Disconnect the oil control valve connector, if equipped.
  16.  
  17. Remove the cylinder head cover.
  18.  
  19. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  20.  
  21. Measure the valve clearance at A . If the clearance exceeds specifications, replace the adjustment shim.

    Click image to see an enlarged view

    Fig. Valve clearance checking positions-2.0L (LF) and 2.3L (L3) engines

  22.  
  23. Turn the crankshaft clockwise 360 degrees until the No. 4 piston is at TDC. Measure the valve clearance at B . If the clearance exceeds specifications, replace the adjustment shim.
  24.  
  25. Repeat this procedure for all the camshafts.
  26.  
  27. Remove the right side halfshaft from the joint shaft on Mazda 6 models.
  28.  
  29. Remove the engine front cover lower and upper blind plugs and the cylinder block lower blind plug.
  30.  
  31. Install tool 49 JE01 061.
  32.  
  33. 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).

    Click image to see an enlarged view

    Fig. Remove the engine front cover lower blind plug-2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

    Fig. Remove the engine front cover upper blind plug-2.0L (LF) and 2.3L (L3) engines



    Click image to see an enlarged view

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

  34.  
  35. Loosen the timing chain as follows:
    1. Unlock the chain tensioner ratchet using a screwdriver.
    2.  
    3. Turn the exhaust camshaft clockwise using a wrench on the cast hexagon portion of the camshaft and loosen the timing chain.
    4.  
    5. Place a M6 x 1.0 length bolt: 0.99-1.37 inch (25-35mm) at the engine front cover upper blind plug and secure the timing chain guide at the location where the chain tension is released.

      Click image to see an enlarged view

      Fig. Loosen the timing chain tension, refer to the text for procedure-2.0L (LF) and 2.3L (L3) engines



      Click image to see an enlarged view

      Fig. Hold the exhaust camshaft using a wrench on the cast hexagon portion of the camshaft and remove the exhaust camshaft sprocket-2.0L (LF) and 2.3L (L3) engines

    6.  

  36.  
  37. Hold the exhaust camshaft using a wrench on the cast hexagon portion of the camshaft and remove the exhaust camshaft sprocket.
    NOTE
    The cylinder head and camshaft caps are numbered and must be reassembled in their original locations. When removing a when removed, keep the caps with the cylinder head they were removed from, do not switch the caps.

  38.  
  39. Loosen the camshaft cap bolts using 2-3 passes in the sequence illustrated.
  40.  
  41. Once all the bolts have been removed, remove the caps, keeping them in the original positions and remove the camshafts.
  42.  
  43. Remove the tappets and select the proper adjustment shim. The formula for selecting a shim is as follows:
    1. Removed shim thickness + measured valve clearance-standard valve clearance 0.0098 inch (0.25mm) for the intake and 0.0118 inch (0.30mm) for the exhaust.
    2.  

  44.  
  45. Install the adjustment shim.
  46.  
  47. Set the cam position of the number 1 cylinder at Top Dead center (TDC) and install the camshaft.
  48.  
  49. Temporarily install the camshaft caps in their original positions.
  50.  
  51. Tighten the camshaft cap bolt in two steps:
    1. Step 1: 44-71 inch lbs. (5-8 Nm).
    2.  
    3. Step 2 : 10.4-12.5 ft. lbs. (14-17 Nm).
    4.  

  52.  
  53. Install the exhaust camshaft sprocket and hand tighten the bolt.
  54.  
  55. Install tool 49 UN30 3465 as illustrated on the camshaft.

    Click image to see an enlarged view

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

  56.  
  57. Remove the M6 x 1.0 bolt from the engine front cover to tension the timing chain.
  58.  
  59. 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).
  60.  
  61. Hold the exhaust camshaft using a wrench on the cast hexagon portion of the camshaft and tighten the exhaust camshaft sprocket bolt to 51-55 ft. lbs. (69-75 Nm).
  62.  
  63. Remove the tools from the camshaft and from the block lower blind plug.
  64.  
  65. Rotate the engine two full turns clockwise to TDC. If not aligned, remove the crankshaft pulley lockbolt, remove the tappet and repeat the adjustment shim selection and replacement procedure.
  66.  
  67. Apply sealant to the engine front cover upper blind plug and tighten to 71-101 inch lbs. (8-11 Nm).
  68.  
  69. Install the cylinder block lower blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  70.  
  71. Install a new engine front cover blind plug and tighten to 7.4-10 ft. lbs. (10-14 Nm).

    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-2.0L (LF) and 2.3L (L3) engines

  72.  
  73. Install the right side halfshaft from the joint shaft on Mazda 6 models.
  74.  
  75. Install the cylinder head cover.
  76.  
  77. Install the PCV hose, if equipped.
  78.  
  79. Connect the oil control valve connector, if equipped.
  80.  
  81. Install the ignition coils.
  82.  
  83. Connect the wiring harness.
  84.  
  85. Connect the negative battery cable and install the battery cover.
  86.  
  87. Install the plug hole plate.
  88.  
  89. Install the splash shield, under cover and wheel.
  90.  

 
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