Mazda Car 2005-06

Valve Lash (Clearance) Adjustment

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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.

The valve clearance should be measured with the engine cold, the specifications are:



Intake: 22-28mm (0.0087-0.0110 in.)
 
Exhaust: 0.27-0.33 (0.0107-0.0129 in.)
 

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the battery cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the plug hole plate.
  8.  
  9. Disconnect the ventilation hose.
  10.  
  11. Remove the front suspension tower bar.
  12.  
  13. Remove the CMP sensor.
  14.  
  15. Disconnect the OCV connector.
  16.  
  17. Disconnect the P/S pressure switch connector.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Remove the cylinder head cover.
  22.  
  23. Remove the drive belt.
  24.  
  25. Remove the engine front cover lower blind plug.

    Click image to see an enlarged view

    Fig. Remove the engine front cover lower blind plug-MX-5 Miata



    Click image to see an enlarged view

    Fig. Remove the engine front cover upper blind plug-MX-5 Miata



    Click image to see an enlarged view

    Fig. Remove the cylinder block upper blind plug and install tool 303-507-MX-5 Miata

  26.  
  27. Remove the engine front cover upper blind plug.
  28.  
  29. Remove the cylinder block lower blind plug.
  30.  
  31. Install tool 303-507 as shown.
  32.  
  33. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position.
  34.  
  35. Loosen the timing chain.
  36.  
  37. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
  38.  
  39. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain.
  40.  
  41. Place a M6 X 1 length bolt at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.

    Click image to see an enlarged view

    Fig. Place a M6 X 1 length bolt at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released-MX-5 Miata



    Click image to see an enlarged view

    Fig. Hold the exhaust camshaft using a suitable wrench on the cast hexagon-MX-5 Miata



    Click image to see an enlarged view

    Fig. Remove the exhaust camshaft sprocket-MX-5 Miata

  42.  
  43. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as illustrated.
  44.  
  45. Remove the exhaust camshaft sprocket.
  46.  
  47. Loosen the camshaft cap bolts in several passes in the order shown.
    NOTE
    The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. Do not mix the caps.

  48.  
  49. Remove the camshafts.
  50.  
  51. Remove the tappet.
  52.  
  53. Select proper adjustment tappet using the following formula:
    1. New adjustment tappet = removed tappet thickness + Measured valve clearance - standard valve clearance. For the intake: 0.25 mm (0.0098 in.). For the exhaust: 0.30 mm (0.0118 in.).
    2.  

  54.  
  55. Install the camshaft with No.1 cylinder camshaft lobes aligned with the TDC position.
  56.  
  57. Tighten the camshaft cap bolt using two steps, first to 5-9 Nm (44-80 in. lbs.), then to 14-17 Nm (10-12.5 ft. lbs.).
  58.  
  59. Install a new washer.
  60.  
  61. Install the exhaust camshaft sprocket.
    NOTE
    Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.

  62.  
  63. Install the tool on the camshaft as shown.

    Click image to see an enlarged view

    Fig. Install the tool illustrated on the camshaft-MX-5 Miata



    Click image to see an enlarged view

    Fig. Install a new washer-MX-5 Miata

  64.  
  65. Remove the M6 X 1.0 bolt from the engine front cover to apply tension to the timing chain.
  66.  
  67. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position.
  68.  
  69. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown.
  70.  
  71. Tighten the exhaust camshaft sprocket lock bolt to 69-75 Nm (51-55 ft. lbs.)
  72.  
  73. Remove the tool from the camshaft.
  74.  
  75. Remove the tool from the block lower blind plug.
  76.  
  77. Rotate the crankshaft clockwise two turns until the TDC position.
  78.  
  79. If not aligned, loosen the crankshaft pulley lock bolt and repeat the procedure.
  80.  
  81. Apply silicone sealant to the engine front cover upper blind plug.
  82.  
  83. Install the engine front cover upper blind plug and tighten to 8-11 Nm (71-101 in. lbs.)
  84.  
  85. Install the cylinder block lower blind plug and tighten to 18-2 Nm (13-16 ft. lbs.)
  86.  
  87. Install the new engine front cover lower blind plug and tighten to 10-14 Nm (89-123 ft. lbs.)
  88.  
  89. Install the drive belt.
  90.  
  91. Measure the valve clearance.
  92.  
  93. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
  94.  
  95. Measure the valve clearance at point A in the illustration.
  96.  
  97. If the valve clearance is out of the specification, adjust it.
  98.  
  99. Turn the crankshaft 360 degrees clockwise so that the No.4 piston is at TDC of the compression stroke.
  100.  
  101. Measure the valve clearance at B in the illustration.
  102.  
  103. If the valve clearance is out of the specification, adjust it.
  104.  
  105. Install the cylinder head cover.
  106.  
  107. Install the ignition coils.
  108.  
  109. Connect the OCV connector.
  110.  
  111. Install the CMP sensor.
  112.  
  113. Install the front suspension tower bar.
  114.  
  115. Connect the ventilation hose.
  116.  
  117. Install the air cleaner.
  118.  
  119. Install the plug hole plate.
  120.  
  121. Install the battery and battery tray.
  122.  

Inspection



The valve clearance should be measured with the engine cold, the specifications are:



Intake: 22-28mm (0.0087-0.0110 in.)
 
Exhaust: 0.27-0.33 (0.0107-0.0129 in.)
 

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove the battery cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the plug hole plate.
  8.  
  9. Disconnect the ventilation hose.
  10.  
  11. Remove the front suspension tower bar.
  12.  
  13. Remove the CMP sensor.
  14.  
  15. Disconnect the OCV connector.
  16.  
  17. Disconnect the P/S pressure switch connector.
  18.  
  19. Remove the ignition coils.
  20.  
  21. Remove the cylinder head cover.
  22.  
  23. Measure the valve clearance.

    Click image to see an enlarged view

    Fig. Measure the valve clearance at points A and B-MX-5 Miata

  24.  
  25. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
  26.  
  27. Measure the valve clearance at point A in the illustration.
  28.  
  29. If the valve clearance is out of the specification, adjust it.
    NOTE
    Make sure to note down the measured values for choosing the suitable replacement tappets.

  30.  
  31. Turn the crankshaft 360 degrees clockwise so that the No.4 piston is at TDC of the compression stroke.
  32.  
  33. Measure the valve clearance at point B in the illustration.
  34.  
  35. If the valve clearance is out of the specification, adjust it.
  36.  
  37. Install the cylinder head cover.
  38.  
  39. Install the ignition coils.
  40.  
  41. Connect the P/S pressure switch connector.
  42.  
  43. Connect the OCV connector.
  44.  
  45. Install the CMP sensor.
  46.  
  47. Install the front suspension tower bar.
  48.  
  49. Connect the ventilation hose.
  50.  
  51. Install the plug hole plate.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Install the battery cover.
  56.  

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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