Mazdamanuals.com

TIMING CHAIN REMOVAL/INSTALLATION [L8, LF, L3]

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Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [L8, LF, L3].)

1.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

2.  Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo])

3.  Remove the tire (RH). (See PRECAUTION (SUSPENSION).)

4.  Remove the under cover.

5.  Loosen the water pump pulley bolt and removal the drive belt. (See DRIVE BELT REPLACEMENT [L8, LF, L3].)

6.  Remove the CKP sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [L8, LF, L3].)

7.  Drain the engine oil. (See ENGINE OIL REPLACEMENT [L8, LF, L3, L3 Turbo].)

8.  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. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

9.  Remove the front drive shaft (RH) from the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)

10.  Remove in the order indicated in the table.

11.  Install in the reverse order of removal.

12.  Start the engine and:

•  Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.

•  Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [L8, LF, L3].)

13.  Perform a road test.

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1	Dipstick
2	Cylinder head cover (See Cylinder Head Cover Installation Note.)
3	Crankshaft pulley lock bolt (See Crankshaft Pulley Lock Bolt Removal Note.) (See Crankshaft Pulley Lock Bolt Installation Note.)
4	Crankshaft pulley
5	Water pump pulley
6	Drive belt idler pulley
7	No.3 engine mount rubber and No.3 engine joint bracket (See No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Removal Note.) (See No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Installation Note.)
8	Front oil seal (See Front Oil Seal Removal Note.) (See Front Oil Seal Installation Note.)
9	Engine front cover (See Engine Front Cover Installation Note.)
10	Chain tensioner (See Chain Tensioner Removal Note.)
11	Tensioner arm
12	Chain guide
13	Timing chain (See Timing Chain Installation Note.)
14	Seal (L3)
15	Oil pump chain tensioner
16	Oil pump chain guide
17	Oil pump sprocket (See Oil Pump Sprocket Removal Note.) (See Oil Pump Sprocket Installation Note.)
18	Oil pump chain
19	Crankshaft sprocket

Crankshaft Pulley Lock Bolt Removal Note

1.  Remove the cylinder block lower blind plug.

2.  Install the SST.

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3.  Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is attached to the SST).

4.  Hold the crankshaft pulley by using the SSTs.

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No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Removal Note

1.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L8, LF, L3].)

2.  Install the SST using the following procedure.

Caution

•  Refer to the SST instruction manual for the basic handing procedure.

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(1)  Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.

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(2)  Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)

Note

•  When setting the SST on the right side, make sure it doesn’t interfere with the ABS (ABS/TCS) HU/CM or the DSC HU/CM. (5 speed ATX)

(3)  Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.

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*  :If equipped.

(4)  Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.

(5)  Make sure each joint is securely tightened.

3.  Support the engine using the SST.

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Note

•  The SST (49E 017 5A0) can be used in place of the SST (49C 017 5A0).

Front Oil Seal Removal Note

1.  Remove the oil seal using a screwdriver as shown.

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Chain Tensioner Removal Note

1.  Using a thin screwdriver, hold the chain tensioner ratchet lock mechanism away from the ratchet stem.

2.  Slowly compress the tensioner piston.

3.  Hold the tensioner piston using a 1.5 mm {0.059 in} wire or paper clip.

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Oil Pump Sprocket Removal Note

1.  Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the oil pump against rotation as shown in figure.

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2.  Remove the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Oil Pump Sprocket Installation Note

1.  Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the oil pump against rotation as shown in figure.

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2.  Install the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Timing Chain Installation Note

1.  Install the SST to the camshaft as shown.

Europe

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Except Europe

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2.  Install the timing chain.

3.  Remove the retaining wire or paper clip from the auto tensioner to apply tension to the timing chain.

Engine Front Cover Installation Note

1.  Apply silicone sealant to the engine front cover as shown.

Caution

•  Install the engine front cover within 10 minutes of applying the silicone sealant.

Without crescent grooves at joint sections of cylinder head and cylinder block

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With crescent grooves at joint sections of cylinder head and cylinder block

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2.  Install the engine front cover bolts in the order as shown.

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Bolt No.	Tightening torque
1—18	8.0—11.5 N·m {81.6—117.2 kgf·cm,70.9—101.7 in·lbf}
19—22	40—55 N·m {4.1—5.6 kgf·m, 29.7—40.5 ft·lbf}

Front Oil Seal Installation Note

1.  Apply clean engine oil to the oil seal.

2.  Push the oil seal slightly in by hand.

3.  Compress the oil seal using the SST and a hammer.

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No.3 Engine Mount Rubber and No.3 Engine Joint Bracket Installation Note

1.  Tighten the stud bolt of the No.3 engine mount bracket.

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2.  Install the No.3 engine mount rubber hand-tighten.

3.  Tighten the No.3 engine joint bracket is attached and bolts, nuts in the order as shown.

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Crankshaft Pulley Lock Bolt Installation Note

1.  Install the SST to the camshaft as shown.

Europe

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Except Europe

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2.  Verify that cylinder No.1 is at TDC of the compression stroke. (Position crank weight contacts SST.)

3.  To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0 length 25—35 mm {0.99—1.37 in}), fix the crankshaft pulley to the engine front cover.

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4.  Install the SSTs to the crankshaft pulley, lock the crankshaft against rotation, and tighten the crankshaft pulley lock bolt using the following two steps.

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5.  Tighten the crankshaft pulley lock bolt using the following two steps.

(1)  Tighten to 96—104 N·m {9.8—10.6 kgf·m, 70.9—76.7 ft·lbf}

(2)  Tighten 87°—93°

6.  Remove the M6 x 1.0 bolt.

7.  Remove the SST from the camshaft.

8.  Remove the SST from the cylinder block lower blind plug.

9.  Rotate the crankshaft clockwise two turns until the TDC position.

•  If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

10.  Install the cylinder block lower blind plug.

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Cylinder Head Cover Installation Note

1.  Apply silicone sealant to the mating faces as shown.

Caution

•  Install the cylinder head cover within 10 minutes of applying the silicone sealant.

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2.  Install the cylinder head cover with a new gasket.

3.  Tighten the bolts in the order shown.

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