Mazda 3 Service Manual: Variable Valve Timing Actuator 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”..

CAUTION:

• Variable valve timing actuator cannot be disassembled because it is a precision unit.

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 cylinder head cover..

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

9. Remove the drive belt..

10. Remove the front drive belt idler pulley..

11. Remove the engine front cover lower blind plug.

12. Remove the engine front cover upper blind plug.

13. Remove the cylinder block lower blind plug.

14. 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.

15. Install the SST

.

16. 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.)

17. Loosen the timing chain using the following procedure.

a. Insert a suitable bolt (M6 X 1.0, length 25—35 mm {1.0—1.3 in})

into the engine front cover upper service hole 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. Drain the engine oil in the chain tensioner.

NOTE:

• The plunger of the chain tensioner will be pushed in by rotating the exhaust camshaft. As a result, engine oil leakage will occur.

i. Set a wrench on the cast hexagon of the exhaust camshaft and one on the cast hexagon of the intake camshaft.

ii. While holding the intake camshaft so that it does not rotate, move the wrench on the exhaust camshaft side back and forth. (Repeat approx. 10 times)

c. Remove the wrench set to the intake camshaft.

d. Using the SST (48 G010 4A0)

, release the chain tensioner ratchet lock.

49 G010 4A0 component parts

i. Seat the nut to the cast hexagon stud and tighten by hand. At this time, leave the handle lever removed.

ii. Set the stud in the engine front cover lower service hole. (Tighten by hand until the hexagon contacts the engine front cover)

iii. Rotate the stud counterclockwise and align it with the tensioner release arm insertion hole to the 2 o'clock position.

iv. Insert the tensioner release arm into the tensioner release arm insertion hole of the stud. (Insert until seated to the nut)

v. Assemble the handle lever to the stud.

vi. Assemble the 49 G010 403

(Tensioner release guide) and flange bolt together and set it to the installation area of the idler pulley. (Tighten flange bolt by hand)

vii. Rotate counterclockwise slowly until the handle lever contacts the tensioner release guide. The ratchet lock will release by rotating to the position which contacts the tensioner release guide.

NOTE:

• If the tensioner release arm cannot be deformed and removed by hand, turn the nut and then remove it.

  

  
  

e. Verify that the ratchet lock is correctly released using the following procedure.

i. Hold the handle lever using the left hand.

ii. With the right hand, move the wrench set to the exhaust camshaft back and forth. At this time, if the handle lever does not thrust back in conjunction with the movement of the wrench, the ratchet lock is released.

• If the handle lever thrusts back in line with the movement of the wrench, the ratchet lock is not released. If this occurs, release the lock using the following procedure.

NOTE:

• Continue to perform the following procedure until the handle lever does not thrust back. If it does not unlock, further rotate the handle lever as the chain tensioner position has deviated.

Lock is not released

• While slowly rotating the handle lever counterclockwise, (while pressing tensioner release guide ahead), move the wrench set to the exhaust camshaft back and forth.

  

  
  

f. While applying pressure to exhaust camshaft with the right hand in the clockwise direction, crimp the bolt set in the procedure (1) approx. 5 mm using the left hand. Fix the tensioner arm.

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

CAUTION:

• Perform the work carefully so that the washer does not drop out.

19. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.

20. Remove the OCV..

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

NOTE:

• The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.

22. Remove the variable valve timing actuator and intake camshaft as a single unit.

23. Remove the variable valve timing actuator using the following procedures.

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 installation bolt.

24. Install the variable valve timing actuator using the following procedures.

CAUTION:

• When the variable valve timing actuator is replaced with a new one, mark it in the same location as the old one.

a. Secure the camshaft in a vise.

b. Install a new washer.

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

NOTE:

• If the alignment marks on the variable valve timing actuator are not available, refer to the “TIMING CHAIN ASSEMBLY” in the engine workshop manual and perform the sprocket position alignment again.

d. Tighten the variable valve timing actuator installation bolt.

Tightening torque

• 69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}

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

.)

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

27. 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.

28. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure. However, do not apply it to the end journal of the intake camshaft.

29. Carefully apply adhesive agent (Loctite 518 or 962T) to the area indicated in the figure so that it does not leak into the sliding part, then apply the gear oil (SAE No. 90 or equivalent) to the journal.

Adhesive agent thickness

• 0.5—1.5 mm {0.02—0.05 in}

30. Temporarily tighten the camshaft cap bolts evenly in 2—3 steps.

NOTE:

• Do not tighten the bolts during this step.

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

Tightening torque

• Step 1: 5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}

• Step 2: 14—17 N·m {1.5—1.7 kgf·m, 11—12 ft·lbf}

32. Install the OCV..

33. Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

CAUTION:

• Install a new washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer.

• Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.

34. Install the SST

on the camshaft as shown in the figure.

35. Remove the bolt (M6 X 1.0, length 25—35 mm {1.0—1.3 in}

) from the engine front cover upper service hole, and apply tension to the timing chain.

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

.)

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

Tightening torque

• 69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}

38. Remove the SST

from the camshaft.

39. Remove the SST

installed to the cylinder block lower blind plug hole.

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

• If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 34.

41. Install the cylinder block lower blind plug.

Tightening torque

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

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

CAUTION:

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

Tightening torque

• 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

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

Tightening torque

• 10—14 N·m {102—142 kgf·cm, 89—123 in·lbf}

44. Install the front drive belt idler pulley..

45. Install the drive belt..

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

47. Install the cylinder head cover..

48. Connect the ventilation hose..

49. Install the ignition coils..

50. Install the high pressure fuel pump and high pressure fuel pump cover..

51. Install the charge air cooler..

52. Connect the negative battery cable..

53. Install the battery cover..