Mazda 3 manuals

Mazda 3 Service Manual: Variable Valve Timing Actuator Removal/Installation [Mzr 2.0, Mzr 2.5]

Mazda 3 Service Manual / Engine / General / Variable Valve Timing Actuator Removal/Installation [Mzr 2.0, Mzr 2.5]

NOTE:

1. Remove the battery cover..

2. Disconnect the negative battery cable.

3. Remove the plug hole plate..

4. Disconnect the wiring harness.

5. Remove the ignition coils..

6. Remove the spark plugs..

7. Remove the ventilation hose.

8. Remove the oil level gauge.

9. Remove the cylinder head cover..

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

11. Remove the generator drive belt with the A/C drive belt still installed and set it out of the way. (MZR 2.0).

12. Remove the drive belt. (MZR 2.5).

13. Remove the engine front cover lower blind plug.


14. Remove the engine front cover upper blind plug.


15. Disconnect the drive shaft (RH) from joint shaft, set the drive shaft (RH) out of the way. (MTX).

16. Remove the cylinder block lower blind plug, and install the SST.


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

and stops.)

18. Loosen the timing chain using the following procedure.

a. Insert a suitable bolt (M6 X 1.0, length 2535 mm {1.01.3 in})

into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)


b. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.


c. Using a Hex bit socket (2.5 mm {0.098 in})

or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.


d. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.


NOTE:

e. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.

NOTE:


19. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.


20. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer (The washers may not be installed.) as a single unit.

CAUTION:

NOTE:


21. Remove the OCV..

22. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.

NOTE:


23. Remove the variable valve timing actuator and the camshaft on the intake air side as a single unit.

24. Remove the variable valve timing actuator.

a. Mark the camshaft and variable valve timing actuator as shown in the figure to make sure they are installed in their original position.


b. Secure the camshaft in a vise.


c. Loosen the variable valve timing actuator tightening bolt.

25. Install a new washer. (Except MZR 2.0 (ATX).)

NOTE:


26. Install the variable valve timing actuator.

NOTE:

a. Secure the camshaft in a vise.

b. Align the marks of the camshaft and variable valve timing actuator.

c. Tighten variable valve timing actuator tightening bolt.

NOTE:

27. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST

.)

28. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.


29. With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timing actuator and the camshaft on the intake air side as a single unit.

30. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.


31. Temporarily tighten the camshaft cap bolts evenly in 23 steps.

32. Tighten the camshaft cap bolts in the order shown in the following two steps.


33. Install the OCV..

34. Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer (Except MZR 2.0 (ATX).) as a single unit.

CAUTION:

NOTE:


35. Install the SST

on the camshaft as shown in the figure.


36. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 2535mm {1.01.3 in})

, and apply tension to the timing chain.

37. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.


38. Remove the SST

from the camshaft.

39. Remove the SST

installed in the cylinder block lower blind plug hole.

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

41. Install the cylinder block lower blind plug.


42. Connect the drive shaft (RH) to joint shaft. (MTX).

43. Apply the silicone sealant and install the engine front cover upper blind plug.


CAUTION:

44. Install a new engine front cover lower blind plug.


45. Install the drive belt. (MZR 2.5).

46. Install the generator drive belt. (MZR 2.0).

47. Install the aerodynamic under cover No.2 and splash shield as a single unit..

48. Install the cylinder head cover..

49. Install the oil level gauge.

50. Install the ventilation hose.

51. Install the spark plugs..

52. Install the ignition coils..

53. Connect the wiring harness.

54. Install the plug hole plate..

55. Connect the negative battery cable..

56. Install the battery cover..

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