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Valve Clearance Adjustment

WARNING: This page is about a different car, the 2004 Mazda 3. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  2. Remove the battery cover.
  3. Disconnect the negative battery cable.
  4. Disconnect the wiring harness.
  5. Disconnect the OCV connector (L3).
  6. Remove the following parts:
    1. Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION SYSTEM) .)
    2. Engine under cover and splash shield (RH).
    3. Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION .)
    4. Ventilation hose.
    5. Cylinder head cover.
    6. Engine front cover lower blind plug.
      Fig 1: Locating Engine Front Cover Lower Blind Plug
      G00973724Courtesy of MAZDA MOTORS CORP.
    7. Engine front cover upper blind plug.
    8. Cylinder block lower blind plug.
    Fig 2: Locating Engine Front Cover Upper Blind Plug
    G00973725Courtesy of MAZDA MOTORS CORP.
  7. Install the SST  as shown in the figure.
    Fig 3: Installing Special Service Tool
    G00973726Courtesy of MAZDA MOTORS CORP.
  8. Turn the crankshaft clockwise the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is attached to the SST)  .
  9. Loosen the timing chain.
    1. Unlock the chain tensioner ratchet using a suitable screwdriver or equivalent tool.
    2. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain.
    3. Placing the suitable bolt (M6 X 1.0 length 25mm-35mm {0.99-1.37in})  at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
    Fig 4: Loosening Timing Chain
    G00973727Courtesy of MAZDA MOTORS CORP.
  10. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
    Fig 5: Removing Exhaust Camshaft Sprocket
    G00973728Courtesy of MAZDA MOTORS CORP.
  11. Remove the exhaust camshaft sprocket.
    Fig 6: Removing Exhaust Camshaft Sprocket
    G00973729Courtesy of MAZDA MOTORS CORP.
    12. NOTE:
    • The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.
    Fig 7: Camshaft Cap Bolt Loosening Sequence
    G00973730Courtesy of MAZDA MOTORS CORP.
  12. Loosen the camshaft cap bolts in 2-3 passes in the order shown in the figure.
  13. Remove the camshaft.
  14. Remove the tappet.
  15. Select proper adjustment shim.

    New Adjustment Shim=Removed Shim Thickness + Measured Valve Clearance - Standard Valve Clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in}) 

    Standard [Engine Cold] 

    IN: 0.22-0.28 mm {0.0087-0.0110 in} 

    EX: 0.27-0.33 mm {0.0107-0.0129 in} 

  16. Install the camshaft with No. 1 cylinder aligned with the TDC position.
  17. Tighten the camshaft cap bolt with the following 2 steps.

    Tightening Torque 

    1. 5.0-8.0 N.m {51.0-81.5 kgf.cm, 44.3-70.8 in.lbf} 
    2. 14-17 N.m {1.43-1.73 kgf.m, 10.4-12.5 ft.lbf} 

    18. NOTE:
    • Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.
    Fig 8: Installing Exhaust Camshaft Sprocket
    G00973731Courtesy of MAZDA MOTORS CORP.
  18. Install the exhaust camshaft sprocket.
  19. Install the SST  to the camshaft as shown in the figure.
    Fig 9: Installing Special Service Tool To Camshaft
    G00973732Courtesy of MAZDA MOTORS CORP.
  20. Remove the (M6 X 1.0 length 25mm-35mm {0.99-1.37in})  bolt from the engine front cover to apply tension to the timing chain.
  21. Turn the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is attached to the SST)  .
  22. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
  23. Tighten the exhaust camshaft sprocket lock bolt.

    Tightening Torque 

    69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf} 

    Fig 10: Tightening Exhaust Camshaft Sprocket Lock Bolt
    G00973733Courtesy of MAZDA MOTORS CORP.
  24. Remove the SST  from the camshaft.
  25. Remove the SST  from the block lower blind plug.
  26. Rotate the crankshaft clockwise two turns until the TDC position.
    • If not aligned, loosen the crankshaft pulley lock bolt and repeat from step  14.
  27. Apply silicone sealant to the engine front cover upper blind plug.
  28. Install the following parts:
    1. Engine front cover upper blind plug.

      Tightening Torque 

      8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf} 

      Fig 11: Locating Engine Front Cover Upper Blind Plug
      G00973734Courtesy of MAZDA MOTORS CORP.
    2. Cylinder block lower blind plug.

      Tightening Torque 

      18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf} 

      Fig 12: Locating Cylinder Block Lower Blind Plug
      G00973735Courtesy of MAZDA MOTORS CORP.
    3. New engine front cover lower blind plug.

      Tightening Torque 

      10-14 N.m {1.1-1.4 kgf.m, 7.4-10.3 ft.lbf} 

      Fig 13: Locating New Engine Front Cover Lower Blind Plug
      G00973736Courtesy of MAZDA MOTORS CORP.
    4. Cylinder head cover. (See CYLINDER HEAD COVER INSTALLATION NOTE .)
    5. Ventilation hose.
    6. Ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION .)
    7. Engine under cover and splash shield (RH).
    8. Front wheel and tire (RH). (See GENERAL PROCEDURES (SUSPENSION SYSTEM) .)
  29. Connect the OCV connector (L3).
  30. Connect the wiring harness.
  31. Connect the negative battery cable.
  32. Install the battery cover.
  33. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
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