Mazda Car 2005-06

Timing Chain & Sprockets 3

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Removal & Installation



3.0L (Aj) Engine
  1. Install the left side chain assembly as follows:
    1. Make sure the crankshaft keyway is at the 11 O-clock position.
    2.  
    3. Position the mark on the intake camshaft to 9 O-clock.
    4.  
    5. Place the mark on the exhaust camshaft at the 12 O-clock position.

      Click image to see an enlarged view

      Fig. When installing the left side chain, make sure the crankshaft keyway is at the 11 O-clock position-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. When installing the left side chain, Position the mark on the intake camshaft to 9 O-clock and the mark on the exhaust camshaft at the 12 O-clock position-Mazda6 with the 3.0L (AJ) engine

    6.  
    7. Align the colored links on the timing chain with the marks on the timing sprockets.
    8.  
    9. If the timing chain marks cannot be seen, use a marker or paint pen to mark the crankshaft and camshaft marks on the chain as follows:

      Mark any link as the crankshaft link
       
      Count 29 links from the crankshaft mark and place a mark to be used as the exhaust camshaft sprocket mark
       
      Continue counting to the 42 link mark and mark this link as the intake camshaft sprocket mark
       

    10.  

  2.  
  3. Install the left hand chain in this order:
    NOTE
    The chain guide should be installed to the actuator and allowed to hang freely when the bolts are installed. Do not hold the guide up when installing the bolts. The actuator causes wear to an O-ring and holding the guide will increase wear.



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

    1. Install the left side camshaft caps. Refer to the camshaft removal procedure earlier in this section

      Click image to see an enlarged view

      Fig. If the timing chain marks cannot be seen, use a marker or paint pen to mark the crankshaft and camshaft marks on the chain. Refer to the text for marking steps.-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. Install the left side timing chain in numerical order and align the colored links with the timing marks on the sprockets-Mazda6 with the 3.0L (AJ) engine

    2.  
    3. Install the left side chain tensioner as follows:
      NOTE
      Minimal force should be used to retract the piston, if binding occurs remove then reinstall the tensioner is the vise.



      Place the tensioner in a vise with jaw protectors
       
      Use a small screwdriver to hold the tensioner ratchet lock mechanism away from the ratchet stem
       



      Slowly compress the tensioner piston and install a paper clip to hold the piston
       
      Install the tensioner, tighten the bolts to 15-22 ft. lbs. (20-30 Nm) and remove the paper clip
       

    4.  

  4.  
  5. Install the right side chain assembly as follows:
    1. Make sure the crankshaft keyway is at the 3 O-clock position.
    2.  
    3. Place the mark on the exhaust camshaft at the 12 O-clock position.
    4.  
    5. Position the mark on the intake camshaft to 3 O-clock.

      Click image to see an enlarged view

      Fig. When installing the right side chain, make sure the crankshaft keyway is at the 3 O-clock position-Mazda6 with the 3.0L (AJ) engine



      Click image to see an enlarged view

      Fig. When installing the right side chain, Position the mark on the exhaust camshaft to 12 O-clock and the mark on the intake camshaft at the 3 O-clock position-Mazda6 with the 3.0L (AJ) engine

    6.  
    7. Align the colored links on the timing chain with the marks on the timing sprockets.
    8.  
    9. If the timing chain marks cannot be seen, use a marker or paint pen to mark the crankshaft and camshaft marks on the chain as follows:

      Mark any link as the crankshaft link
       
      Count 29 links from the crankshaft mark and place a mark to be used as the exhaust camshaft sprocket mark
       
      Continue counting to the 42 link mark and mark this link as the intake camshaft sprocket mark
       

    10.  

  6.  
  7. Install the left hand chain in this order:
    NOTE
    The chain guide should be installed to the actuator and allowed to hang freely when the bolts are installed. Do not hold the guide up when installing the bolts. The actuator causes wear to an O-ring and holding the guide will increase wear.



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

    1. Install the right side camshaft caps. Refer to the camshaft removal procedure earlier in this section

      Click image to see an enlarged view

      Fig. Install the right side timing chain in numerical order and align the colored links with the timing marks on the sprockets-Mazda6 with the 3.0L (AJ) engine

    2.  
    3. Install the right side chain tensioner as follows:
      NOTE
      Minimal force should be used to retract the piston, if binding occurs remove then reinstall the tensioner is the vise.



      Place the tensioner in a vise with jaw protectors
       
      Use a small screwdriver to hold the tensioner ratchet lock mechanism away from the ratchet stem
       



      Slowly compress the tensioner piston and install a paper clip to hold the piston
       
      Install the tensioner, tighten the bolts to 15-22 ft. lbs. (20-30 Nm) and remove the paper clip.
       

    4.  

  8.  
  9. Place the CKP sensor pulse wheel with the Front mark facing towards you, using the keyway on the same side as the empty space as illustrated.

    Click image to see an enlarged view

    Fig. Place the CKP sensor pulse wheel with theFrontmark facing towards you, using the keyway on the same side as the empty space as shown-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Apply a 0.24 inch (6mm) bead of silicone sealant to the locations illustrated and install the front cover-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Tighten the front cover bolts in this sequence-Mazda6 with the 3.0L (AJ) engine

  10.  
  11. Apply a 0.24 inch (6mm) bead of silicone sealant to the locations illustrated and install the front cover.
  12.  
  13. Tighten the front cover bolts in the sequence illustrated and tighten the retainers to 15-20 ft. lbs. (20-30 Nm).
  14.  
  15. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as illustrated.
  16.  
  17. Apply clean oil to the seal and push the seal in by hand.
  18.  
  19. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm).
  20.  
  21. Seal the crankshaft pulley using a silicone sealant.

    Click image to see an enlarged view

    Fig. Assemble the seal using part (A) of tool 49 UN01 002 and tool 49 UN01 002 as shown-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the seal using the installation tools until the seal is recessed 0-0.039 inch (0-1mm)-Mazda6 with the 3.0L (AJ) engine



    Click image to see an enlarged view

    Fig. Install the pulley using the tools shown-Mazda6 with the 3.0L (AJ) engine

  22.  
  23. Install the pulley using the tools illustrated.
  24.  
  25. While holding the pulley, tighten the crankshaft pulley bolt as follows:
    1. Tighten to 88 ft. lbs. (120 Nm).
    2.  
    3. Loosen one full turn.
    4.  
    5. Tighten to 35-39 ft. lbs. (47-53 Nm).
    6.  
    7. Tighten 85-95 degrees.
    8.  

  26.  
  27. Install the no. 3 engine mount rubber.
  28.  
  29. When installing the No. 3 engine joint bracket, tighten the No.3 mount bracket bolts and nuts in the order illustrated as follows:
    1. Bolt 1: 55-77 ft. lbs. (74-105 Nm).
    2.  
    3. Bolts 2, 3 and 4: 31-44 ft. lbs. (43-60 Nm).

      Click image to see an enlarged view

      Fig. Tighten the No. 3 engine joint bracket as shown-Mazda6 models with the 3.0L (AJ) engine

    4.  

  30.  
  31. Install the right hand valve cover.
  32.  
  33. Install the right hand engine hanger.
  34.  
  35. Install the left hand valve cover.
  36.  
  37. Install the dipstick tube.
  38.  
  39. Apply clean engine oil to the camshaft seal and install using the tools illustrated. The seal should be recessed 0.10-0.11 inch (2.5-3mm).

    Click image to see an enlarged view

    Fig. Install the camshaft oil seal-Mazda6 with the 3.0L (AJ) engine

  40.  
  41. Install a new water pump drive belt pulley using tool 49 UN21 1185.
  42.  
  43. Install the water pump drive belt.
  44.  
  45. Install the plug hole plate.
  46.  
  47. Install the remaining components in the reverse order of removal.
  48.  
  49. Chain the engine oil and filter.
  50.  
  51. Check all fluid levels and replenish as necessary.
  52.  
  53. Road test the vehicle.

    Click image to see an enlarged view

    Fig. Install a new water pump drive belt pulley using tool 49 UN21 1185-Mazda6 models with the 3.0L (AJ) engine

  54.  

Mazdaspeed6


Click image to see an enlarged view

Fig. Exploded view of the timing chain assembly and related components-Mazdaspeed6

  1. Before servicing the vehicle, refer to the precautions section.
  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. Disconnect the Camshaft Position (CMP) and power steering oil pump connectors.
  34.  
  35. Remove the ignition coils, spark plugs, valve cover and accessory drive belt.
  36.  
  37. Remove the Crankshaft Position (CKP) sensor.
  38.  
  39. Remove the power steering oil pump with the lines attached and position aside.
  40.  
  41. Disconnect the right hand driveshaft from the joint shaft.
  42.  
  43. Remove the cylinder block lower blind plug.
  44.  
  45. Install tool 49 JE01 061.
  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. Hold the crankshaft pulley using the tools illustrated and remove the bolt.
  50.  
  51. Remove the crankshaft pulley.

    Click image to see an enlarged view

    Fig. Install tool 49 JE01 061-Mazdaspeed6



    Click image to see an enlarged view

    Fig. Install tools 205-072-02 and 205-126 to hold the crankshaft pulley using the tools illustrated and remove the bolt-Mazdaspeed6

  52.  
  53. Remove the water pump pulley.
  54.  
  55. Remove the drive belt idler pulley.
  56.  
  57. Disconnect the engine ground.
  58.  
  59. Install an engine support device such as 49 E017 5A0.
  60.  
  61. Remove the No. 3 engine mount and joint.
  62.  
  63. Remove the engine front cover and oil seal.
  64.  
  65. 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-Mazdaspeed6

  66.  
  67. Remove the tensioner arm, chain guide and timing chain.
  68.  

To install:

Click image to see an enlarged view

Fig. Install tool 49 UN30 3465 on the camshaft-Mazdaspeed6

  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-Mazdaspeed6



    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-Mazdaspeed6

    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 0.086-0.126 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).

      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-Mazdaspeed6



      Click image to see an enlarged view

      Fig. Engine front cover bolts tightening sequence-Mazdaspeed6

    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).

    Click image to see an enlarged view

    Fig. No. 3 engine mount bracket stud bolt locations-Mazdaspeed6



    Click image to see an enlarged view

    Fig. Tighten the No. 3 joint bracket bolts and nuts in the order shown-Mazdaspeed6

  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-Mazdaspeed6

  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 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.

  38.  
  39. Assemble the high pressure line pipe.
  40.  
  41. 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).
  42.  
  43. Tighten the water outlet case installation bolts to 13-16 ft. lbs. (18-22 Nm).
  44.  
  45. Install the quick release connector.
  46.  
  47. Install the remaining components in the reverse order of removal.
  48.  
  49. Change the engine oil.
  50.  
  51. Start the engine.
  52.  
  53. Inspect for the following:

    Pulley and belt for run-out and contact
     
    Ignition timing, idle speed and exhaust emissions
     
    All remaining components for proper operation.
     

  54.  
  55. Verify that the high pressure fuel pump is assembled securely.
  56.  
  57. Drive the vehicle starting from a standstill and brake suddenly five to six times at a low speed.
  58.  
  59. Stop the vehicle and verify from outside the vehicle that there is no fuel leakage around the high pressure fuel pump.
  60.  

 
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