Mazda 3 manuals

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

Mazda 3 Service Manual / Engine / Belts, Hoses, Pulleys / Timing Chain Removal/Installation [Mzr 2.3 Disi Turbo]

WARNING:

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:



1

Cylinder head cover

(SeeCylinder Head Cover Removal Note.)

(SeeCylinder Head Cover Installation Note.)

2

Crankshaft pulley lock bolt

(SeeCrankshaft Pulley Lock Bolt Removal Note.)

(SeeCrankshaft Pulley Lock Bolt Installation Note.)

3

Crankshaft pulley

4

Water pump pulley

5

Drive belt idler pulley

6

Drive belt idler pulley

7

No. 3 engine mount

(SeeNo.3 Engine Mount Removal Note.)

(SeeNo.3 Engine Mount Installation Note)

8

Front oil seal

(See FRONT OIL SEAL REPLACEMENT [MZR 2.3 DISI Turbo].)

9

Engine front cover

(SeeEngine Front Cover Installation Note.)

10

Chain tensioner

(SeeChain Tensioner Removal Note.)

11

Tensioner arm

12

Chain guide

13

Timing chain

(SeeTiming Chain Installation Note.)

14

Oil pump chain tensioner

15

Oil pump chain guide

16

Oil pump driven sprocket

(SeeOil Pump Driven Sprocket Removal/Installation Note.)

17

Oil pump chain

18

Crankshaft sprocket

19

Oil pump drive sprocket

(SeeOil Pump Drive Sprocket Installation Note.)


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:

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.

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:

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



No.

Tightening Torque

1―18

811 Nm {82112 kgfcm, 7197 inlbf}

19―22

4055 Nm {4.15.6 kgfm, 3040 ftlbf}


No.3 Engine Mount Installation Note

NOTE:

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


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.



No.

Tightening torque

1

75104 Nm {7.710 kgfm, 5676 ftlbf}

2

7193 Nm {7.39.4 kgfm, 5368 ftlbf}


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:

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)

.

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.

10. Install the cylinder block lower blind plug.


Cylinder Head Cover Installation Note

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



CAUTION:

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


3. Install the wiring harness bracket.



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