Mazda Car 2002-04

Valve Lash (Clearance) Adjustment 2

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2.3L & 2.5L Engines




NOTE
With the engine cold, standard valve clearance is 0.011-0.012 in. (0.27-0.31mm) on intake and exhaust sides.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  4.  
  5. Measure the valve clearance at A . Turn the crankshaft clockwise 240 degrees until the No. 3 piston is at TDC. Measure the valve clearance at B . Turn the crankshaft clockwise 240 degrees until the No. 5 piston is at TDC. Measure the valve clearance at C .
    NOTE
    If the valve clearance exceeds the standard, replace the adjustment shim.



    Click image to see an enlarged view

    Fig. Valve clearance checking positions-6-cylinder engine

  6.  
  7. Turn the crankshaft clockwise until the cam, on the camshaft requiring the adjustment shim replacement, is positioned straight up.

    Click image to see an enlarged view

    Fig. Camshaft cap bolt removal positions-6-cylinder engine-refer to text

  8.  
  9. Camshaft cap bolts as follows:


    1. For right-hand (right-hand) exhaust side shim removal use 1 .
    2.  
    3. For right-hand (right-hand) intake side shim removal use 2 .
    4.  
    5. For left-hand (left-hand) intake side shim removal use 3 .
    6.  
    7. For left-hand (left-hand) exhaust side shim removal use 4 .
    8.  

  10.  
  11. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes.
  12.  
  13. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp).
  14.  
  15. Position special tool 49-T012-001 toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement.
  16.  
  17. Position the notch of the tappet to allow a small prytool to be inserted.
  18.  
  19. Set the special tool on the tappet by its notch. Tighten the mounting bolt B securing it on the shaft.
  20.  
  21. Tighten bolt C and press down the tappet.
  22.  
  23. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet. Remove the shim with a magnet.
  24.  
  25. 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-T012-001.
  26.  
  27. Remove special tools 49-T012-002, 003 and 004 and tighten the camshaft cap bolts to 100-125 inch lbs. (11-14 Nm).
  28.  
  29. Repeat the procedure for all necessary adjustment shims. Check the valve clearance.
  30.  

2.3L (Kj) & 2.5L (Kl) Engines



This procedure for the 2.5L (KL) engine valve adjustment is for 626 models only. The Millenia model equipped with the 2.5L engine is equipped with hydraulic lash adjusters and no adjustment is possible or necessary.

  1. Before servicing the vehicle, refer to the Precautions section.
    NOTE
    With the engine cold, standard valve clearance on the 2.5L (KL) engine is 0.0097-0.0124 inch (0.245-0.311mm) on intake side and 0.0105-0.0131 inch (0.265-0.335mm) on the exhaust side. On the 2.3L (KJ) the measurement is 0.011-0.012 inch (0.27-0.33mm) on both the intake and exhaust sides.

  2.  
  3. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  4.  
  5. Measure the valve clearance at A . Turn the crankshaft clockwise 240 degrees until the No. 3 piston is at TDC. Measure the valve clearance at B . Turn the crankshaft clockwise 240 degrees until the No. 5 piston is at TDC. Measure the valve clearance at C .
    NOTE
    If the valve clearance exceeds the standard, replace the adjustment shim.



    Click image to see an enlarged view

    Fig. Valve clearance checking positions-6-cylinder engine

  6.  
  7. Turn the crankshaft clockwise until the cam, on the camshaft requiring the adjustment shim replacement, is positioned straight up.

    Click image to see an enlarged view

    Fig. Camshaft cap bolt removal positions-6-cylinder engine-refer to text

  8.  
  9. Camshaft cap bolts as follows:


    1. For right-hand exhaust side shim removal use A .
    2.  
    3. For right-hand intake side shim removal use B .
    4.  
    5. For left-hand intake side shim removal use C .
    6.  
    7. For left-hand exhaust side shim removal use D .
    8.  

  10.  
  11. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes.
  12.  
  13. Align the mark on the 49-T012-002 (shaft) with the mark on the 49-T012-003 (clamp).
  14.  
  15. Position special tool 49-T012-001 toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement.
  16.  
  17. Position the notch of the tappet to allow a small prytool to be inserted.
  18.  
  19. Set the special tool on the tappet by its notch. Tighten the mounting bolt B securing it on the shaft.
  20.  
  21. Tighten bolt C and press down the tappet.
  22.  
  23. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet. Remove the shim with a magnet.
  24.  
  25. 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-T012-001.
  26.  
  27. Remove special tools 49-T012-002, 003 and 004 and tighten the camshaft cap bolts to 100-125 inch lbs. (11-14 Nm).
  28.  
  29. Repeat the procedure for all necessary adjustment shims. Check the valve clearance.

    Click image to see an enlarged view

    Fig. Install special tools 49-T012-002 and 003, using the camshaft cap bolt holes-6-cylinder engine



    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)-6-cylinder engine



    Click image to see an enlarged view

    Fig. Position special tool 49-T012-001 toward the center of the cylinder head and mount it on the shaft where the adjustment shim needs replacement-6-cylinder engine



    Click image to see an enlarged view

    Fig. Tighten the mounting boltBsecuring it on the shaft. Tighten boltCand press down the tappet-6-cylinder engine



    Click image to see an enlarged view

    Fig. Using a small prytool, pry the adjustment shim upwards through the notch on the tappet-6-cylinder engine

  30.  

2.3L (L3) Engine




NOTE
With the engine cold, standard valve clearance is 0.087-0.0110 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 ignition coils.
  10.  
  11. Disconnect the Oil Control Valve (OCV) connector.
  12.  
  13. Remove the right front wheel, under cover and splash shield.
  14.  
  15. Remove the Positive Crankcase Ventilation (PCV) hose.
  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.
  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 engine front cover lower and upper blind plugs and the cylinder block lower blind plug.
  28.  
  29. Install tool 49 JE01 061.
  30.  
  31. 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).
  32.  
  33. 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.
    6.  

  34.  
  35. 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.

  36.  
  37. Loosen the camshaft cap bolts using 2-3 passes in the sequence illustrated.
  38.  
  39. Once all the bolts have been removed, remove the caps, keeping them in the original positions and remove the camshafts.
  40.  
  41. 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.  

  42.  
  43. Install the adjustment shim.
  44.  
  45. Set the cam position of the number 1 cylinder at Top Dead center (TDC) and install the camshaft.
  46.  
  47. Temporarily install the camshaft caps in their original positions.
  48.  
  49. 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.  

  50.  
  51. Install the exhaust camshaft sprocket and hand tighten the bolt.
  52.  
  53. Install tool 49 UN30 3465 as illustrated on the camshaft.
  54.  
  55. Remove the M6 x 1.0 bolt from the engine front cover to tension the timing chain.
  56.  
  57. 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).
  58.  
  59. 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).
  60.  
  61. Remove the tools from the camshaft and from the block lower blind plug.
  62.  
  63. 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.
  64.  
  65. Apply sealant to the engine front cover upper blind plug and tighten to 71-101 inch lbs. (8-11 Nm).
  66.  
  67. Install the cylinder block lower blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  68.  
  69. Install a new engine front cover blind plug and tighten to 7.4-10 ft. lbs. (10-14 Nm).
  70.  
  71. Install the cylinder head cover.
  72.  
  73. Install the PCV hose.
  74.  
  75. Connect the OCV connector.
  76.  
  77. Install the ignition coils.
  78.  
  79. Connect the wiring harness.
  80.  
  81. Connect the negative battery cable and install the battery cover.
  82.  
  83. Install the plug hole plate.
  84.  
  85. Install the under cover, splash shield and wheel.
  86.  

3.0L (Aj) Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Mark the position of the hydraulic lash adjusters to assure they are assembled in their original position



    Negative battery cable
     
    Camshaft followers
     
    Hydraulic lash adjusters
     

  4.  
  5. Inspect the adjusters for scoring or uneven wear in the bore and replace them as required.
  6.  

To install:

  1. Install or connect the following:

    Hydraulic lash adjusters after lubricating them with clean engine oil
     
    Camshaft followers
     
    Negative battery cable
     

  2.  

Except 2.3L & 2.5L Engines




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

  1. Before servicing the vehicle, refer to the precautions in the beginning of this 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-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 which 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.  

Mazdaspeed6



  1. Before servicing the vehicle, refer to the precautions section.
    NOTE
    With the engine cold, standard valve clearance is 0.087-0.0110 inch (0.22-0.28mm) on the intake side and 0.0107-0.0129 inch (0.27-0.33mm) on the exhaust side.



    Click image to see an enlarged view

    Fig. Valve clearance checking positions-Mazdaspeed6

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the right side front tire.
  6.  
  7. Remove the under cover.
  8.  
  9. Remove the right side splash shield.
    NOTE
    If the high pressure fuel pump is removed, replace the O-ring with a new one.

  10.  
  11. Remove the charge air cooler cover.
  12.  
  13. Disconnect the spill valve control solenoid valve connector.
  14.  
  15. Disconnect the quick release connector on the high pressure fuel pump.
  16.  
  17. Remove the battery and battery tray.
    WARNING
    If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When removing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump joint nut has rotated, replace the high pressure fuel pump with a new one.

  18.  
  19. Disconnect the high pressure line pipe of the high pressure fuel pump.
  20.  
  21. Fix the joint nut with a wrench on the high pressure fuel pump side.
  22.  
  23. Loosen the high pressure line pipe installation nut.
  24.  
  25. Drain and recycle the engine coolant.
  26.  
  27. Loosen the water outlet case installation bolts securing the high pressure line pipe.
  28.  
  29. Remove the high pressure fuel pump.
  30.  
  31. Remove the high pressure fuel pump cover.
  32.  
  33. Remove the ignition coils, spark plugs, valve cover and accessory drive belt.
  34.  
  35. Measure the valve clearance by turning the crankshaft clockwise until the No. 1 piston is at Top Dead Center (TDC).
  36.  
  37. Measure the valve clearance at A . If the clearance exceeds specifications, replace the adjustment shim.
  38.  
  39. 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.
  40.  
  41. Repeat this procedure for all the camshafts.
  42.  
  43. Remove the engine front cover lower and upper blind plugs and the cylinder block lower blind plug.
  44.  
  45. Install tool 49 JE01 061.

    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061-Mazdaspeed6



    Click image to see an enlarged view

    Fig. Loosen the timing chain tension, refer to the text for procedure-Mazdaspeed6



    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-Mazdaspeed6

  46.  
  47. 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).
  48.  
  49. 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.
    6.  

  50.  
  51. 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.

  52.  
  53. Loosen the camshaft cap bolts using 2-3 passes in the sequence illustrated.
  54.  
  55. Once all the bolts have been removed, remove the caps, keeping them in the original positions and remove the camshafts.
  56.  
  57. 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.  

  58.  
  59. Install the adjustment shim.
  60.  
  61. Set the cam position of the number 1 cylinder at Top Dead center (TDC) and install the camshaft.
  62.  
  63. Temporarily install the camshaft caps in their original positions.
  64.  
  65. 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.  

  66.  
  67. Install the exhaust camshaft sprocket and hand tighten the bolt.
  68.  
  69. 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-Mazdaspeed6

  70.  
  71. Remove the M6 x 1.0 bolt from the engine front cover to tension the timing chain.
  72.  
  73. 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).
  74.  
  75. 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).

    Click image to see an enlarged view

    Fig. Camshaft cap bolt tightening sequence-Mazdaspeed6

  76.  
  77. Remove the tools from the camshaft and from the block lower blind plug.
  78.  
  79. 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.
  80.  
  81. Apply sealant to the engine front cover upper blind plug and tighten to 71-101 inch lbs. (8-11 Nm).
  82.  
  83. Install the cylinder block lower blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
  84.  
  85. Install a new engine front cover blind plug and tighten to 7.4-10 ft. lbs. (10-14 Nm).
  86.  
  87. Install the high pressure fuel pump cover and tighten to 13-16 ft. lbs. (18-22 Nm).
    CAUTION
    If the high pressure fuel pump installation bolts are tightened with the high pressure fuel pump tilted, the high pressure fuel pump may not operate correctly. Tighten the high pressure fuel pump installation bolts in a few passes with equal torque. Tighten to 76-101 inch lbs. (8.5-11.5 Nm).


    WARNING
    If the high pressure fuel pump joint nut is loosened, fuel leakage may occur resulting in death or serious injury, or damage to the equipment or the vehicle. Fuel can also irritate the skin and eyes. When installing the high pressure line pipe, always tighten the high pressure line pipe installation nut while fixing the high pressure fuel pump joint nut with a wrench. If the high pressure fuel pump joint nut has rotated, replace the high pressure fuel pump with a new one.

  88.  
  89. Assemble the high pressure line pipe.
  90.  
  91. Fix the joint nut with a wrench on the high pressure fuel pump side. Tighten the high pressure line pipe installation nut to 17-26 ft. lbs. (23-35 Nm).
  92.  
  93. Tighten the water outlet case installation bolts to 13-16 ft. lbs. (18-22 Nm).
  94.  
  95. Install the quick release connector.
  96.  
  97. Install the remaining components in the reverse order of removal.
  98.  
  99. Verify that the high pressure fuel pump is assembled securely.
  100.  
  101. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.
  102.  
  103. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the high pressure fuel pump.
  104.  

 
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