Mazda 3 Service Manual: Timing Chain Removal/Installation [Mzr 2.3 Disi Turbo]

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 injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”..

1. Remove the battery cover..

2. Disconnect the negative battery cable..

3. Remove the charge air cooler..

4. Remove the high pressure fuel pump and high pressure fuel pump cover..

5. Remove the ignition coils..

6. Disconnect the ventilation hose from the cylinder head cover..

7. Remove the coolant reserve tank with the hose still connected and set it out of the way..

8. Remove the front wheel and tire. (RH).

9. Remove the aerodynamic under cover No.2 and splash shield as a single unit..

10. Remove the nut shown in the figure and set the power steering pipe component out of the way.

11. Loosen the water pump pulley bolts before removing the drive belt.

12. Remove the drive belt..

13. Remove the crankshaft position (CKP) sensor..

14. Remove in the order indicated in the table.

15. Install in the reverse order of removal.

16. Start the engine, and inspect and adjust the following:

• Leakage of engine oil..

• Runout and contact of pulley and belt.

• Ignition timing, idle speed and idle mixture..

Cylinder Head Cover Removal Note

1. Set the wiring harness out of the way.

2. Remove the wiring harness bracket with the wiring harness still connected and set it out of the way.

3. Remove the wiring harness bracket.

4. Loosen the cylinder head cover bolts in the order shown in the figure.

Crankshaft Pulley Lock Bolt Removal Note

1. Remove the cylinder block lower blind plug.

2. Rotate the crankshaft in the direction of the engine rotation until the No. 1 piston is at the point prior to top dead center (TDC) of the compression stroke.

3. Install the SST

.

4. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of the compression stroke. (Until the counterweight contacts the SST

and stops.)

5. Hold the crankshaft pulley using the SSTs

.

No.3 Engine Mount Removal Note

1. Remove the air cleaner..

2. Install the SST

using the following procedures.

CAUTION:

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

a. Remove the installation bolt for the bracket securing the lower radiator hose.

b. Set the bracket securing the lower radiator hose aside to prevent it from interfering with the front shaft of the SST

(right side)

c. As shown in the figure, set the rear shafts of the SST

to the left and right shock absorber bolts.

d. Install front foot No.2 to the left/right front shaft of the SST

, then align the groove of the front shaft of the SST

with the folded up part of the vehicle as shown in the figure.

e. Adjust the positions of the SST

side bars so that they are the same height (left and right) and horizontal. Make sure each joint is securely tightened.

Chain Tensioner Removal Note

1. Press the timing chain tensioner ratchet to the left using a thin flathead screwdriver (precision screwdriver) to unlock the plunger.

2. Slowly press the plunger back in the direction shown in the figure while pressing the ratchet.

3. Release the ratchet with the plunger still pressed down.

4. Press-in the plunger until the ratchet position is as indicated in the figure, and then insert the wire or paper clip to lock the plunger.

Oil Pump Driven Sprocket Removal/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.

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

Tightening torque

• 20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}

Oil Pump Drive Sprocket Installation Note

1. Assemble the oil pump drive sprocket as shown in the figure.

Timing Chain Installation Note

1. Install the SST

to the camshaft as shown in the figure.

2. Install the timing chain.

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

Engine Front Cover Installation Note

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

CAUTION:

• Install the engine front cover before the applied silicone sealant starts to harden.

• Completely remove any oil, dirt, sealant, or other foreign matter adhering to the engine front cover and engine front cover installation surface. If any oil, dirt, sealant, or other foreign matter is not removed from the space between the engine front cover and engine front cover installation surface, it may cause a sealing malfunction.

Thickness

• A: 2.2—3.2 mm {0.09—0.12 in}

• B: 1.5—2.5 mm {0.06—0.098 in}

2. Tighten the engine front cover installation bolts in the order as shown in the figure.

No.3 Engine Mount Installation Note

NOTE:

• Retighten the No.3 engine mount stud bolts when the No.3 engine mount nuts are loosened.

1. Tighten the No.3 engine mount stud bolts.

Tightening torque

• 7—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

2. Temporarily tighten the No.3 engine mount installation bolts and nuts.

3. Tighten the No.3 engine mount installation bolts and nuts in the order as shown in the figure.

Crankshaft Pulley Lock Bolt Installation Note

1. Install the SST

to the camshaft as shown in the figure.

2. Verify that the No.1 piston is at TDC of the compression stroke. (The position counterweight contacts the SST

.)

3. To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0

), fix the crankshaft pulley to the engine front cover.

NOTE:

• Do not tighten the crankshaft pulley lock bolt during this step.

4. Hold the crankshaft pulley using the SSTs

.

5. Tighten the crankshaft pulley lock bolt in the following two steps using the SST (49 D032 316)

.

Tightening torque

• Step 1: 96—104 N·m {9.8—10 kgf·m, 71—76 ft·lbf}

• Step 2: 87—93°

6. Remove the bolt (M6 X 1.0

) installed to the crankshaft pulley.

7. Remove the SST

from the camshaft.

8. Remove the SST

installed to the cylinder block lower blind plug hole.

9. Rotate the crankshaft clockwise two turns and inspect the valve timing.

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

10. Install the cylinder block lower blind plug.

Tightening torque

• 18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}

Cylinder Head Cover Installation Note

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

CAUTION:

• Install the cylinder head cover before the applied silicone sealant starts to harden.

Thickness

• 5.0 mm {0.20 in}

2. Tighten the cylinder head cover bolts in the order shown in the figure.

Tightening torque

• 8.0—9.5 N·m {82—96 kgf·cm, 71—84 in·lbf}

3. Install the wiring harness bracket.