Mazda Car 2005-06

Timing Chain & Sprockets 1

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Removal & Installation





Click image to see an enlarged view

Fig. Exploded view of the timing chain and related components-MX-5 Miata

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Disconnect the ventilation hose.
  8.  
  9. Loosen the water pump pulley bolt and removal the drive belt.
  10.  
  11. Remove the front suspension tower bar.
  12.  
  13. Remove the Camshaft Position (CMP) sensor.
  14.  
  15. Disconnect the OCV connector.
  16.  
  17. Remove the ignition coils.
  18.  
  19. Remove the drive belt.
  20.  
  21. Remove the under cover.
  22.  
  23. Remove the Crankshaft Position (CKP) sensor.
  24.  
  25. Remove the P/S oil pump with the oil hose still connected and position the P/S oil pump so that it is out of the way.
  26.  
  27. Move the cooler pipe No.3 and heater pipe slightly out of the way.
  28.  
  29. Remove the dipstick.
  30.  
  31. Remove the cylinder head cover.
  32.  
  33. Remove the crankshaft pulley lock bolt as follows:
    1. Remove the cylinder block lower blind plug.

      Click image to see an enlarged view

      Fig. Remove the cylinder block lower blind plug-MX-5 Miata



      Click image to see an enlarged view

      Fig. Install tool 303-507 in the lower blind plug opening-MX-5 Miata

    2.  
    3. Install tool 303-507.
    4.  
    5. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight contacts tool 303-507).
    6.  
    7. Hold the crankshaft pulley using the tools shown in the illustration.
    8.  
    9. Remove the crankshaft pulley lock bolt.
    10.  

  34.  
  35. Remove the crankshaft pulley.
  36.  
  37. Remove the front oil seal as follows:
    1. Cut the oil seal lip using a razor knife.
    2.  
    3. Remove the oil seal using a screwdriver wrapped with a rag.

      Click image to see an enlarged view

      Fig. Hold the crankshaft pulley using the tools shown-MX-5 Miata

    4.  

  38.  
  39. Remove the water pump pulley.
  40.  
  41. Remove the drive belt idler pulley.
  42.  
  43. Remove the engine front cover.
  44.  
  45. Remove the oil seal using a screwdriver.
  46.  
  47. Remove the chain tensioner as follows:
    1. Using a thin screwdriver, hold the chain tensioner ratchet lock mechanism away from the ratchet stem.
    2.  
    3. Slowly compress the tensioner piston.
    4.  
    5. Hold the tensioner piston using a 1.5 mm (0.059 in.) wire or paper clip.

      Click image to see an enlarged view

      Fig. Hold the tensioner piston using a 1.5 mm (0.059 in.) wire or paper clip-MX-5 Miata

    6.  

  48.  
  49. Remove the tensioner arm.
  50.  
  51. Remove the chain guide.
  52.  
  53. Remove the timing chain
  54.  

To install:

  1. Install tool 303-465 onto the camshaft as illustrated.

    Click image to see an enlarged view

    Fig. Install tool 303-465 onto the camshaft-MX-5 Miata

  2.  
  3. Install the timing chain.
  4.  
  5. Install the chain guide. Tighten the bolt to 8-11.5 Nm (71-101 inch lbs.).
  6.  
  7. Install the tensioner arm. Tighten the bolt to 8-11.5 Nm (71-101 inch lbs.).
  8.  
  9. Remove the retaining wire or paper clip from the chain tensioner to apply tension to the timing chain.
  10.  
  11. Install the oil seal.
  12.  
  13. Install the engine front cover as follows:
    1. Install the front oil seal before installing the cover.
    2.  
    3. Apply silicone sealant to the engine front cover as illustrated.
      CAUTION
      Install the engine front cover within 10 minutes of applying the silicone sealant.


      NOTE
      Silicone sealant is not need in area C as shown.

    4.  

  14.  
  15. Apply silicone sealant at location A . The sealant thickness should be 2-3mm (0.079-0.118 inch. At location B the sealant thickness should be 1.5-2.5mm (0.059-0.098 inch). Refer to the illustration for locations.

    Click image to see an enlarged view

    Fig. Apply sealant at the locations shown in the illustration. Refer to the illustration for sealant thickness-MX-5 Miata



    Click image to see an enlarged view

    Fig. Front cover bolt locations-MX-5 Miata

  16.  
  17. Install the front cover. On bolts 1 through 18 tighten to 8-11.5 Nm (71-101 in. lbs). Bolts 19 through 22, tighten to 20-55 Nm (30-40 ft. lbs.). Refer to the illustration for locations.
  18.  
  19. Install the crankshaft pulley lock bolt as follows:
    1. Install tool shown in the illustration on the camshaft.

      Click image to see an enlarged view

      Fig. Install tool shown onto the camshaft-MX-5 Miata

    2.  
    3. Verify that cylinder No.1 is at TDC of the compression stroke. (Crankshaft balance weight contacts tool 303-507)
    4.  
    5. Position the crankshaft pulley by temporarily tightening it and, using a suitable length bolt 25-35mm( 0.99-1.37 in.), fix the crankshaft pulley to the engine front cover.
    6.  
    7. Install the tools illustrated to the crankshaft pulley, lock the crankshaft against rotation.
    8.  
    9. Tighten the crankshaft pulley lock bolt to 96-104 Nm (71-77 ft. lbs.), plus 87-93 degrees.
    10.  
    11. Remove the bolt.

      Click image to see an enlarged view

      Fig. Position the crankshaft pulley by temporarily tightening it using a suitable length bolt-MX-5 Miata



      Click image to see an enlarged view

      Fig. Install the tools shown onto the crankshaft pulley to lock the crankshaft against rotation-MX-5 Miata

    12.  
    13. Remove the tool the camshaft.
    14.  
    15. Remove tool from the cylinder block lower blind plug.
    16.  
    17. Remove the tool from the crankshaft pulley.
    18.  
    19. Rotate the crankshaft clockwise two turns until the TDC position.
    20.  
    21. If not aligned, loosen the crankshaft pulley lock bolt and repeat from the first step.
    22.  
    23. Install the cylinder block lower blind plug and tighten to 18-22 Nm (13-16 ft. lbs.).
    24.  

  20.  
  21. Install the cylinder head cover bolts and tighten in the sequence illustrated to 8-10.5 Nm (70-93 n. lbs.).
  22.  
  23. Install the remaining components in the reverse order of removal.

    Click image to see an enlarged view

    Fig. Prior to install the cylinder head cover, apply a 4-6mm (0.16-0.23 in) bead of sealant at these locations-MX-5 Miata



    Click image to see an enlarged view

    Fig. Cylinder head cover torque sequence-MX-5 Miata

  24.  

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.  

 
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