Accepted Answer

HI,

 

Ok, for engine timing, you will need a special timing tool to set cam and crankshaft properly. all parts stores carry the set:

 

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Removal & Installation

2.0L (Lf) & 2.3L (L3) Engines

1. Remove the plug hole plate and bracket.
2. Remove the accelerator cable and bracket.
3. Remove the battery cover and disconnect the negative battery cover.
4. Remove the ignition coils.
5. Remove the right hand front wheel.
6. Remove the engine under cover and splash shields.
7. Remove the Crankshaft Position (CKP) sensor.
8. Remove the accessory drive belt.
9. Remove the A/C compressor and set aside with the lines attached.
10. Remove the coolant reservoir tank and set aside with the lines still attached.
11. Remove the cylinder head cover.
12. Remove the cylinder block lower blind plug.
13. Install tool 49 JE01 061.
14. Turn the crankshaft clockwise until the crankshaft is in the number 1 cylinder Top Dead Center position (the balance weight should be attached to tool 49 JE01 061).
15. Hold the crankshaft pulley using the tools illustrated and remove the bolt.
16. Remove the crankshaft pulley.
    
    

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    Fig. Install tool 49 JE01 061-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

    
    
    

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    Fig. Install tool 49 JE01 061 to hold the crankshaft pulley using the tools illustrated and remove the bolt-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

17. Remove the water pump pulley.
18. Remove the drive belt tensioner.
19. Remove the No. 3 engine mount and joint bracket as follows:
    1. Install two suitable pieces of wood between the front fender panel and upper apron reinforcement as illustrated. The wood size should be approximately 1.38 inch (35mm) on 4 door models or 2.36 inch (60mm) on 5 door models.
    
    
20. Install an engine support device such as 49 E017 5A0.
    
    

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    Fig. Install two suitable pieces of wood between the front fender panel and upper apron reinforcement-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

21. Remove the engine front cover and oil seal.
22. Unlock the chain tensioner using a suitable tool to slowly compress the tensioner piston. Insert a 0.059 inch (1.5mm) wire or a paper clip to hold the piston in its compressed position.
    
    

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    Fig. Compressing and retaining the chain tensioner piston-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

23. Remove the tensioner arm, chain guide and timing chain.

 

To install:

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Fig. Install tool 49 UN30 3465 on the camshaft-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

 

1. Install tool 49 UN30 3465 as illustrated on the camshaft.
2. Install the timing chain and remove the paper clip or wire retaining the tensioner piston to apply tension to the chain.
3. Install the timing chain guide and tighten the bolts to 71-101 inch lbs. (8-12 Nm).
4. Install the tensioner arm and tighten the bolts to 71-101 inch lbs. (8-12 Nm).
5. Install a new oil seal in the front cover as follows:
   
   

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   Fig. Use seal installer tool 49 H010 401 and a hammer to install the seal-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

   
   
   

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   Fig. The seal should be recessed 0-0.019 inch (0-0.5mm) as shown when properly installed-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

   1. Coat the new seal with clean engine oil.
   2. Push the seal in by hand to get it started.
   3. Use seal installer tool 49 H010 401 and a hammer to install the seal so that it is recessed 0-0.019 inch (0-0.5mm) as shown in the accompanying illustration.
   
   
6. Apply sealant to the engine front cover. At point A the bead should be 0.087-0.125 inch (2.2-3.2mm) thick and at point B the bead should be 0.059-0.098 inch (1.5-2.5mm) thick. Refer to the accompanying illustration for the locations of points A and B. No sealant is needed at the points marked C on 2.3L (L3) engines with variable valve timing.
7. Install the cover within 10 minutes of apply the sealant. Tighten the cover bolts as follows:
   1. Bolts 1 through 18: In sequence to 71-101 inch lbs. (8-12 Nm).
   2. Bolts 19 through 22 : In sequence to 29.7-40.5 ft. lbs. (40-55 Nm).
   3. Bolt 23 : 14.8-22 ft. lbs. (20-30 Nm).
      
      

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      Fig. Apply a bead of sealant to the engine front cover at the locations shown. Refer to the text for the bead thickness-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

      
      
      

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      Fig. Engine front cover bolts tightening sequence-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

      
      
      

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      Fig. Location of the No. 3 engine mount bracket stud bolts-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

   
   
8. Install the No. 3 engine mount and joint bracket as follows:
   1. Tighten the No. 3 mount bracket stud bolts to 62-115 inch lbs. (7-13 Nm). Tighten the stud bolt with the mount nut loosened.
   2. Hand tighten the mount rubber and bracket nuts and bolts, then tighten in the sequence illustrated to 55-77 ft. lbs. (74-105 Nm).
      
      

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      Fig. Tighten the mount rubber and bracket nuts and bolts in the sequence-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

      
      
      

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      Fig. Install and hand tighten the M6 x 1.0 bolt-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

   
   
9. Install tool 49 UN30 3465 as illustrated on the camshaft.
10. Install and hand tighten the M6 x 1.0 bolt as illustrated.
11. Turn the crankshaft clockwise until the crankshaft is in number 1 TDC (the balance weight should be attached to the tool).
12. Hold the crankshaft pulley and tighten the lock bolt in two steps. First tighten to 71-77 ft. lbs. (96-104 Nm). Then final tighten an additional 87-93 degrees.
13. Remove the M6 x 1.0 bolt.
14. Remove the tools from the camshaft and the cylinder block lower blind plug.
15. Rotate the crankshaft clockwise 2 turns until you reach TDC. If not aligned properly, loosen the crankshaft pulley lock bolt and reinstall the lock bolt again using the above procedure and special tools.
16. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
17. Apply a 0.16-0.24 inch (4-7mm) bead of silicone sealant to cylinder head at the areas illustrated. Make sure to install the cover within 10 minutes of applying the sealant.
18. Install the cylinder head cover with a new gasket. Torque the bolts in the sequence illustrated to 71-93 inch lbs. (8-11 Nm).
    
    

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    Fig. Apply silicone sealant to cylinder head at the areas illustrated-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

    
    
    

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    Fig. Tighten the cylinder head cover bolts in the sequence shown-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

19. Install the remaining components in the reverse order of removal.
20. When installing the CKP sensor perform the following:
    1. Remove the cylinder block lower blind plug.
    2. Install tool 49 JE01 061.
    3. Turn the crankshaft clockwise until the crankshaft is in the number 1 cylinder Top Dead Center position (the balance weight should be attached to tool 49 JE01 061).
    4. Using a ruler, mark the center line on the pulse wheel teeth on the crank pulley which is located at the 9th tooth counting counterclockwise from the empty space. Refer to the illustration for more detail.
       CAUTION If you do not mark the center line correctly this will cause improper engine control for the ignition and fuel system, so be sure to mark the line carefully.
       
    5. Install the CKP sensor making sure the mark on the sensor is aligned with the mark on the pulse wheel. Tighten the sensor bolt to 49-66 inch lbs. (5.5-7.5 Nm)and attach the electrical connector.
    6. Remove the tool from the cylinder block lower blind plug.
    7. Rotate the crankshaft clockwise 2 turns until you reach TDC. If not aligned properly, loosen the crankshaft pulley lock bolt and reinstall the lock bolt.
    8. Install the cylinder block blind plug and tighten to 13-16 ft. lbs. (18-22 Nm).
       
       

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       Fig. Using a ruler, mark the center line on the pulse wheel teeth on the crank pulley which is located at the 9th tooth counting counterclockwise from the empty space-Mazda 3 with the 2.0L (LF) and 2.3L (L3) engines

    
    
21. Change the engine oil.
22. Start the engine.
23. Inspect for the following:
    
    Pulley and belt for run-out and contact Any leaking fluids. Ignition timing, idle speed and exhaust emissions All remaining components for proper operation

 

Expert:	Eric
Pos. Feedback:	99.8 %
Accepts:
Answered:	10/24/2009

Automotive Repair Shop Manager

Automotive Repair Shop Manager, Technician/JA Mentor