Mazda Car 2005-06

Timing Chain & Sprockets 2

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Removal & Installation



2.3L (L3) Engine


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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.

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



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    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:

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



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    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).

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      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



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      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).

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



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    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


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Fig. Exploded view of the timing chain assembly and related components-Mazda6 with the 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
       
      Chain guide
       
      Timing chain crankshaft sprocket

      Click image to see an enlarged view

      Fig. Rotate the crankshaft clockwise so the crankshaft keyway is at the 3 O-clock position when removing the right side chain-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Remove right side timing chain in numerical order-Mazda6 with the 3.0L (AJ) engine

       

    4.  

  58.  
  59. Remove the right side camshaft caps. Refer to the camshaft removal procedure earlier in this section
  60.  
  61. Remove the left side chain tensioner and chain assembly as follows:
    1. Rotate the crankshaft clockwise 1 2 / 3 turns until the keyway is at the 11 O-clock position.
    2.  
    3. Remove the chain in this order:

      Chain tensioner
       
      Tensioner arm
       
      Timing chain
       
      Chain guide
       
      Timing chain crankshaft sprocket

      Click image to see an enlarged view

      Fig. Rotate the crankshaft clockwise 12/3turns until the keyway is at the 11 O-clock when removing the left side chain-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Remove left side timing chain in numerical order-Mazda6 with the 3.0L (AJ) engine

       

    4.  

  62.  
  63. Remove the left side camshaft caps. Refer to the camshaft removal procedure earlier in this section
  64.  

To install:

 
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