Mazda MPV 1999-06

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



2.5L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Accessory drive belt
     
    Intake Manifold Runner Control (IMRC) actuator
     
    Spark plug wires
     
    Ignition coil
     
    Exhaust front pipe
     
    Oil pan
     
    Alternator and bracket
     
    A/C compressor
     
    Wiring harness connector bracket
     
    Water pump drive belt and pulley
     
    Camshaft oil seal housing
     
    Valve covers
     
    Right motor mount and bracket
     
    Crankshaft pulley
     
    Front crankshaft seal
     
    Front cover. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Front cover bolt removal sequence-2.5L engine

     



    Crankshaft Position (CKP) sensor pulse wheel
     

  8.  
  9. Rotate the crankshaft so that the keyway is at the 11 o'clock position to locate the crankshaft at TDC for No. 1 cylinder.
  10.  
  11. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck.

    Click image to see an enlarged view

    Fig. Camshaft alignment with the crankshaft in the 11 o-clock position-2.5L engine

  12.  
  13. Rotate the crankshaft so that the keyway is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position.
    NOTE
    Keep all valvetrain components in order for assembly.

  14.  
  15. Remove or disconnect the following:

    Right timing chain tensioner
     
    Right timing chain tensioner arm
     
    Right timing chain and crankshaft timing sprocket
     
    Right bank camshafts
     

  16.  
  17. Rotate the crankshaft 1 and 2 / 3 turns and set the crankshaft keyway at the 11 o-clock position. This places the left bank camshafts in the neutral position.
  18.  
  19. Remove or disconnect the following:

    Left timing chain tensioner
     
    Left timing chain tensioner arm
     
    Left timing chain and crankshaft timing sprocket
     

  20.  

To install:

  1. Prepare the timing chain tensioners for installation as follows:
    1. Place the left chain tensioner in a vise.
    2.  
    3. Using a small prytool, release and hold the timing chain tensioner ratchet/pawl mechanism through the access hole in the timing chain tensioner.

      Click image to see an enlarged view

      Fig. Using a thin prytool, release and hold the timing chain tensioner ratchet/pawl mechanism-2.5L engine

    4.  
    5. Slowly compress the tensioner.
    6.  
    7. Lock the piston with a 1.5mm wire or paperclip.
    8.  
    9. Repeat for the right chain tensioner.
      NOTE
      Be sure that the crankshaft keyway is still at the 11 o'clock position.



      Click image to see an enlarged view

      Fig. Left bank timing chain alignment-2.5L engine

    10.  

  2.  
  3. Install or connect the following:

    Left timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
     
    Left timing chain tensioner arm
     
    Left timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
     

  4.  
  5. Remove the left timing chain tensioner retaining wire.
  6.  
  7. Rotate the crankshaft so that the keyway is at the 3 o'clock position.
  8.  
  9. Install the right bank camshafts with the exhaust camshaft index mark at 12 o-clock and the intake camshaft index mark at 3 o-clock as shown.

    Click image to see an enlarged view

    Fig. Right bank camshaft positioning-2.5L engine



    Click image to see an enlarged view

    Fig. Right bank timing chain alignment-2.5L engine

  10.  
  11. Install or connect the following:

    Right timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
     
    Right timing chain tensioner arm
     
    Right timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
     

  12.  
  13. Remove the right timing chain tensioner retaining wire.
  14.  
  15. Install or connect the following:

    CKP sensor pulse wheel
     
    Front cover. Tighten the bolts in the reverse of the loosening sequence to 15-22 ft. lbs. (20-30 Nm).
     
    Front crankshaft seal
     
    Crankshaft pulley
     

  16.  
  17. Tighten the crankshaft pulley bolt as follows:
    1. Step 1: 88 ft. lbs. (120 Nm)
    2.  
    3. Step 2: Loosen the bolt one turn
    4.  
    5. Step 3: 35-39 ft. lbs. (47-53 Nm)
    6.  
    7. Step 4: Plus 85-95 degrees
    8.  

  18.  
  19. Install or connect the following:

    Right motor mount and bracket
     
    Valve covers
     
    Camshaft oil seal housing
     
    Water pump drive belt and pulley
     
    Wiring harness connector bracket
     
    A/C compressor
     
    Alternator and bracket
     
    Oil pan
     
    Exhaust front pipe
     
    Ignition coil
     
    Spark plug wires
     
    IMRC actuator
     
    Accessory drive belt
     
    Intake manifold
     
    Negative battery cable
     

  20.  
  21. Fill the crankcase to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Accessory drive belt
     
    Intake Manifold Runner Control (IMRC) actuator
     
    Spark plug wires
     
    Ignition coil
     
    Exhaust front pipe
     
    Oil pan
     
    Alternator and bracket
     
    A/C compressor
     
    Wiring harness connector bracket
     
    Water pump drive belt and pulley
     
    Camshaft oil seal housing
     
    Valve covers
     
    Right motor mount and bracket
     
    Crankshaft pulley
     
    Front crankshaft seal
     
    Front cover. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Front cover bolt removal sequence-2.5L engine

     



    Crankshaft Position (CKP) sensor pulse wheel
     

  8.  
  9. Rotate the crankshaft so that the keyway is at the 11 o'clock position to locate the crankshaft at TDC for No. 1 cylinder.
  10.  
  11. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck.

    Click image to see an enlarged view

    Fig. Camshaft alignment with the crankshaft in the 11 o-clock position-2.5L engine

  12.  
  13. Rotate the crankshaft so that the keyway is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position.
    NOTE
    Keep all valvetrain components in order for assembly.

  14.  
  15. Remove or disconnect the following:

    Right timing chain tensioner
     
    Right timing chain tensioner arm
     
    Right timing chain and crankshaft timing sprocket
     
    Right bank camshafts
     

  16.  
  17. Rotate the crankshaft 1 and 2 / 3 turns and set the crankshaft keyway at the 11 o-clock position. This places the left bank camshafts in the neutral position.
  18.  
  19. Remove or disconnect the following:

    Left timing chain tensioner
     
    Left timing chain tensioner arm
     
    Left timing chain and crankshaft timing sprocket
     

  20.  

To install:

  1. Prepare the timing chain tensioners for installation as follows:
    1. Place the left chain tensioner in a vise.
    2.  
    3. Using a small prytool, release and hold the timing chain tensioner ratchet/pawl mechanism through the access hole in the timing chain tensioner.

      Click image to see an enlarged view

      Fig. Using a thin prytool, release and hold the timing chain tensioner ratchet/pawl mechanism-2.5L engine

    4.  
    5. Slowly compress the tensioner.
    6.  
    7. Lock the piston with a 1.5mm wire or paperclip.
    8.  
    9. Repeat for the right chain tensioner.
      NOTE
      Be sure that the crankshaft keyway is still at the 11 o'clock position.



      Click image to see an enlarged view

      Fig. Left bank timing chain alignment-2.5L engine

    10.  

  2.  
  3. Install or connect the following:

    Left timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
     
    Left timing chain tensioner arm
     
    Left timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
     

  4.  
  5. Remove the left timing chain tensioner retaining wire.
  6.  
  7. Rotate the crankshaft so that the keyway is at the 3 o'clock position.
  8.  
  9. Install the right bank camshafts with the exhaust camshaft index mark at 12 o-clock and the intake camshaft index mark at 3 o-clock as shown.

    Click image to see an enlarged view

    Fig. Right bank camshaft positioning-2.5L engine



    Click image to see an enlarged view

    Fig. Right bank timing chain alignment-2.5L engine

  10.  
  11. Install or connect the following:

    Right timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
     
    Right timing chain tensioner arm
     
    Right timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
     

  12.  
  13. Remove the right timing chain tensioner retaining wire.
  14.  
  15. Install or connect the following:

    CKP sensor pulse wheel
     
    Front cover. Tighten the bolts in the reverse of the loosening sequence to 15-22 ft. lbs. (20-30 Nm).
     
    Front crankshaft seal
     
    Crankshaft pulley
     

  16.  
  17. Tighten the crankshaft pulley bolt as follows:
    1. Step 1: 88 ft. lbs. (120 Nm)
    2.  
    3. Step 2: Loosen the bolt one turn
    4.  
    5. Step 3: 35-39 ft. lbs. (47-53 Nm)
    6.  
    7. Step 4: Plus 85-95 degrees
    8.  

  18.  
  19. Install or connect the following:

    Right motor mount and bracket
     
    Valve covers
     
    Camshaft oil seal housing
     
    Water pump drive belt and pulley
     
    Wiring harness connector bracket
     
    A/C compressor
     
    Alternator and bracket
     
    Oil pan
     
    Exhaust front pipe
     
    Ignition coil
     
    Spark plug wires
     
    IMRC actuator
     
    Accessory drive belt
     
    Intake manifold
     
    Negative battery cable
     

  20.  
  21. Fill the crankcase to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold
     
    Accessory drive belt
     
    Intake Manifold Runner Control (IMRC) actuator
     
    Spark plug wires
     
    Ignition coil
     
    Exhaust front pipe
     
    Oil pan
     
    Alternator and bracket
     
    A/C compressor
     
    Wiring harness connector bracket
     
    Water pump drive belt and pulley
     
    Camshaft oil seal housing
     
    Valve covers
     
    Right motor mount and bracket
     
    Crankshaft pulley
     
    Front crankshaft seal
     
    Front cover. Loosen the bolts in the sequence shown.

    Click image to see an enlarged view

    Fig. Front cover bolt removal sequence-3.0L engine

     



    Crankshaft Position (CKP) sensor pulse wheel
     

  8.  
  9. Rotate the crankshaft so that the keyway is at the 11 o'clock position to locate the crankshaft at TDC for No. 1 cylinder.
  10.  
  11. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck.

    Click image to see an enlarged view

    Fig. Camshaft alignment with the crankshaft in the 11 o-clock position-3.0L engine

  12.  
  13. Rotate the crankshaft so that the keyway is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position.
    NOTE
    Keep all valvetrain components in order for assembly.

  14.  
  15. Remove or disconnect the following:

    Right timing chain tensioner
     
    Right timing chain tensioner arm
     
    Right timing chain and crankshaft timing sprocket
     
    Right bank camshafts
     

  16.  
  17. Rotate the crankshaft 1 and 2 / 3 turns and set the crankshaft keyway at the 11 o-clock position. This places the left bank camshafts in the neutral position.
  18.  
  19. Remove or disconnect the following:

    Left timing chain tensioner
     
    Left timing chain tensioner arm
     
    Left timing chain and crankshaft timing sprocket
     

  20.  

To install:

  1. Prepare the timing chain tensioners for installation as follows:
    1. Place the left chain tensioner in a vise.
    2.  
    3. Using a small prytool, release and hold the timing chain tensioner ratchet/pawl mechanism through the access hole in the timing chain tensioner.

      Click image to see an enlarged view

      Fig. Using a thin prytool, release and hold the timing chain tensioner ratchet/pawl mechanism-3.0L engine

    4.  
    5. Slowly compress the tensioner.
    6.  
    7. Lock the piston with a 1.5mm wire or paperclip.
    8.  
    9. Repeat for the right chain tensioner.
      NOTE
      Be sure that the crankshaft keyway is still at the 11 o'clock position.



      Click image to see an enlarged view

      Fig. Left bank timing chain alignment-3.0L engine

    10.  

  2.  
  3. Install or connect the following:

    Left timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
     
    Left timing chain tensioner arm
     
    Left timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
     

  4.  
  5. Remove the left timing chain tensioner retaining wire.
  6.  
  7. Rotate the crankshaft so that the keyway is at the 3 o'clock position.
  8.  
  9. Install the right bank camshafts with the exhaust camshaft index mark at 12 o-clock and the intake camshaft index mark at 3 o-clock as shown.

    Click image to see an enlarged view

    Fig. Right bank camshaft positioning-3.0L engine



    Click image to see an enlarged view

    Fig. Right bank timing chain alignment-3.0L engine

  10.  
  11. Install or connect the following:

    Right timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets.
     
    Right timing chain tensioner arm
     
    Right timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
     

  12.  
  13. Remove the right timing chain tensioner retaining wire.
  14.  
  15. Install or connect the following:

    CKP sensor pulse wheel
     
    Front cover. Tighten the bolts in the reverse of the loosening sequence to 15-22 ft. lbs. (20-30 Nm).
     
    Front crankshaft seal
     
    Crankshaft pulley
     

  16.  
  17. Tighten the crankshaft pulley bolt as follows:
    1. Step 1: 88 ft. lbs. (120 Nm).
    2.  
    3. Step 2: Loosen the bolt one turn.
    4.  
    5. Step 3: 35-39 ft. lbs. (47-53 Nm).
    6.  
    7. Step 4: Plus 85-95 degrees.
    8.  

  18.  
  19. Install or connect the following:

    Right motor mount and bracket
     
    Valve covers
     
    Camshaft oil seal housing
     
    Water pump drive belt and pulley
     
    Wiring harness connector bracket
     
    A/C compressor
     
    Alternator and bracket
     
    Oil pan
     
    Exhaust front pipe
     
    Ignition coil
     
    Spark plug wires
     
    IMRC actuator
     
    Accessory drive belt
     
    Intake manifold
     
    Negative battery cable
     

  20.  
  21. Fill the crankcase to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  

 
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