Mazda 3 manuals

Mazda 3 Service Manual: Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Removal/Installation [Skyactiv G 2.0]

Mazda 3 Service Manual / Engine / General / Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Removal/Installation [Skyactiv G 2.0]

WARNING:

CAUTION:

NOTE:

1. Remove the battery cover..

2. Disconnect the negative battery cable..

3. Remove the plug hole plate..

4. Remove the ignition coil/ion sensors..

5. Remove the cylinder head cover..

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

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

8. Remove the electric variable valve timing motor/driver..

9. Remove the vacuum pump. (Only when hydraulic variable valve timing actuator is removed.).

10. Remove the high pressure fuel pump and rear housing. (Only when hydraulic variable valve timing actuator is removed.).

11. Remove in the order indicated in the table.

12. Install in the reverse order of removal.

13. Start the engine and inspect the following:



1

Oil shower pipe

(See Oil Shower Pipe Installation Note.)

2

Timing chain

(See Timing Chain Removal Note.)

(See Timing Chain Installation Note.)

3

Chain guide (No.1)

4

Electric variable valve timing actuator

(See Electric Variable Valve Timing Actuator Removal Note.)

(See Electric Variable Valve Timing Actuator Installation Note.)

5

OCV

6

Hydraulic variable valve timing actuator and exhaust camshaft component

(See Hydraulic Variable Valve Timing Actuator and Exhaust Camshaft Component Removal Note.)

(See Hydraulic Variable Valve Timing Actuator and Exhaust Camshaft Component Installation Note.)

7

Hydraulic variable valve timing actuator

(See Hydraulic Variable Valve Timing Actuator Removal Note.)

(See Hydraulic Variable Valve Timing Actuator Installation Note.)


Timing Chain Removal Note

1. Set the ground cable and the wiring harness bracket shown in the figure aside.


2. Release the tension on the timing chain using the following procedure:

NOTE:

a. Remove the blind plugs (upper and lower) on the engine front cover service holes.


b. Insert an M6 bolt (3560 mm {1.42.3 in}

length with thread to the end) to the upper service hole and tighten it until it contacts the tensioner arm, then loosen it approx. 180 degrees

. (Set the bolt so that it sits slightly in front of the tensioner arm.)


NOTE:

c. Insert a precision screwdriver into the lower service hole.

d. While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision screwdriver and release the plunger lock.



NOTE:

e. With the plunger lock released, rotate the exhaust camshaft clockwise until the timing chain loosens.


f. With the chain loosened, tighten the M6 bolt in the upper service hole so that the bolt is inserted approx. 5 mm {0.2 in}

additionally to secure the tensioner arm.


NOTE:

g. After securing the tensioner arm, remove the chain guide (No.1).

Electric Variable Valve Timing Actuator Removal Note

CAUTION:

1. Rotate the crankshaft clockwise so that cylinder No.1 is positioned around before top dead center (TDC) as shown in the figure.


NOTE:

2. Mark the timing chain and each actuator so that they can be reassembled in the same condition as before removal.


3. Hold the intake camshaft using a wrench on the cast hexagon and remove the electric variable valve timing actuator installation bolt.


4. Using a screwdriver wrapped in a clean cloth, lightly press the electric variable valve timing actuator to the front and separate the intake camshaft and the actuator.


5. Remove the timing chain from the exhaust and intake camshaft sprockets and set is aside, and remove the electric variable valve timing actuator.


6. Return the timing chain to the exhaust camshaft sprocket, and pull the timing chain up and suspend it using a rope as shown in the figure.


Hydraulic Variable Valve Timing Actuator and Exhaust Camshaft Component Removal Note

CAUTION:

1. Leave the timing chain as it is, which was suspended after electric variable valve timing actuator removal.

2. Temporarily install the cylinder head cover bolt to the position shown in the figure to use it for suspending the timing chain.


3. Loosen the exhaust-side camshaft cap bolts in two or three passes in the order shown in the figure, and remove the camshaft cap.


4. While setting the timing chain aside, remove the hydraulic variable valve timing actuator and the exhaust camshaft as a single unit.


5. Pull up the timing chain and suspend it using a rope as shown in the figure.


Hydraulic Variable Valve Timing Actuator Removal Note

1. Lock the exhaust camshaft against rotation by holding the exhaust camshaft with a vise and securing the cast hexagon with a wrench.


2. Loosen the hydraulic variable valve timing actuator installation bolt and remove the actuator.

Hydraulic Variable Valve Timing Actuator Installation Note

1. When newly replacing the hydraulic variable valve timing actuator, place a mark at the same position as the one placed before removal.

2. Align the knock pin on the end of the exhaust camshaft with the knock pin installation hole on the actuator side, and temporarily assemble the bolt.


3. Lock the exhaust camshaft against rotation by holding the exhaust camshaft with a vise and securing the cast hexagon with a wrench.


4. Tighten the hydraulic variable valve timing actuator installation bolt.

Hydraulic Variable Valve Timing Actuator and Exhaust Camshaft Component Installation Note

1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area (exhaust side) of each journal of the cylinder head.


CAUTION:

2. Remove the rope suspending the timing chain on the exhaust side.

3. While aligning the mark on the timing chain placed during removal with the one on the hydraulic variable valve timing actuator, place the exhaust camshaft component on the cylinder head.


4. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the exhaust camshaft.


5. Apply sealant (Loctite 962T) around journal No.6 of the cylinder head or the exhaust-side rear camshaft cap.


CAUTION:

6. Install the camshaft caps in the marked number order, and temporarily tighten the camshaft cap installation bolts in two or three passes evenly.

7. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure.


Electric Variable Valve Timing Actuator Installation Note

1. When replacing the electric variable valve timing actuator with a new one, place a mark at the same position as the one placed before removal.

2. Remove the rope suspending the timing chain on the intake side.

3. Remove the timing chain from the exhaust and intake camshaft sprockets and set it aside to the rear, then insert the electric variable valve timing actuator between the engine front cover and the cylinder head.


4. Return the timing chain to the exhaust camshaft sprocket.

5. While aligning the mark on the timing chain placed during removal with the one on the electric variable valve timing actuator, engage the chain with the sprocket.


6. Align the knock pin on the end of the intake camshaft with the notch on the actuator side, then assemble the actuator.


NOTE:

7. Hold the intake camshaft using a wrench on the cast hexagon, and tighten the electric variable valve timing actuator installation bolt.


Timing Chain Installation Note

1. Install the chain guide (No.1).

2. Remove the bolt securing the tensioner arm and apply tension to the timing chain.

3. Rotate the crankshaft clockwise two turns and verify that the valve timing is correct.


4. Install the blind plugs (upper and lower) for the engine front cover service holes.


5. Install the ground cable and wiring harness bracket shown in the figure.


Oil Shower Pipe Installation Note

1. Install the oil shower pipe in the order shown in the figure.


Tightening torque

Installation position

Tightening torque

1

912 Nm {92122 kgfcm, 80106 inlbf}

2, 3

8.09.0 Nm {8291 kgfcm, 7179 inlbf}


Electric Variable Valve Timing Actuator Inspection [Skyactiv G 2.0]
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WARNING: A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing. CAUTION: Do not disassemble the electric variable valve timing mo ...

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