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Engine Mechanical - 3.0L: Engine: Assembly

WARNING: Eye protection is required to be worn during the use of compressed air. Failure to wear eye protection could result in possible personal injury.
  1. Clean gasket material, dirt and foreign material from the cylinder block. Wash the cylinder block with a suitable soap and water solution, and dry with compressed air.
  2. If removed, install the crankshaft key into the keyway on the crankshaft.
    Fig 1: Installing Crankshaft Key
    G01151927Courtesy of MAZDA MOTORS CORP.
    3. NOTE: This procedure is for selecting bearings using a new crankshaft.
  3. Select the crankshaft main bearings for each crankshaft journal.
    1. Read the code on the crankshaft flange.
    2. Read the code on the cylinder block rear face.
      3. Fig 2: Reading Code On Crankshaft Flange
      G01151928Courtesy of MAZDA MOTORS CORP.
    3. The first two numbers after the asterisk make up the code for main No. 1 and the next two numbers for main No. 2.
  4. Using the chart, choose a bearing for each main. Match the block and crankshaft code with its corresponding column or row, by reading across the "crankshaft" row and down the "block" column.
    • For example: If the block code is *0609*0711* and the crankshaft code is *8480*8082*, main No. 1 should use grade 1 bearings, as determined by the intersection of the 06 block column and the 84 crankshaft row. Mains 2,3 and 4 should all be grade 2.
      Fig 3: Crankshaft Code Chart
      G01151929Courtesy of MAZDA MOTORS CORP.
  5. Install the main bearings into the cylinder block.
    • The first two numbers after the second asterisk make up the code for main No. 3 and the last two numbers for main No. 4.
      Fig 4: Installing Main Bearings Into Cylinder Block
      G01151930Courtesy of MAZDA MOTORS CORP.
  6. Install the main bearings into the lower cylinder block.
    Fig 5: Installing Main Bearings Into Lower Cylinder Block
    G01151931Courtesy of MAZDA MOTORS CORP.
  7. Install the crankshaft thrust bearing.
    Fig 6: Installing Crankshaft Thrust Bearing
    G01151932Courtesy of MAZDA MOTORS CORP.
  8. Apply SAE 5W-20 motor oil to the crankshaft main and rod bearing journals.
  9. Position the crankshaft in the cylinder block.
    Fig 7: Installing Crankshaft In Cylinder Block
    G01151934Courtesy of MAZDA MOTORS CORP.
    10. CAUTION: The lower cylinder block must be installed and the bolts tightened within four minutes of applying the sealant.
    Fig 8: Applying Silicone Gasket & Sealant To Cylinder Block
    G01151933Courtesy of MAZDA MOTORS CORP.
  10. Apply Silicone Gasket and Sealant to the cylinder block as shown.
    11. CAUTION: Fasteners No. 1, 5, 6, 7, 8 are studs. Fasteners No. 18-22 are M8 x 1.25 mm x 79.3 mm (0.05 in x 3.12 in) bolts. Fasteners No. 2-4, 17 are M8 x 1.25 mm x 95.3 mm (0.05 in x 3.75 in) bolts. Fasteners 9-16 are M10 x 1.5 mm x 106 mm (0.06 in x 4.17 in) bolts. The bolts and studs must be installed in the correct position or engine damage may result.
  11. Position the lower cylinder block and install the bolts and studs.
    • Tighten the bolts and studs in the sequence shown in four stages.
    • Stage 1: Tighten fasteners 1-8 to 25 N.m (2.5 kgf.m , 18 ft.lbf).
    • Stage 2: Tighten fasteners 9-19 to 40 N.m (4.1 kgf.m , 30 ft.lbf).
    • Stage 3: Tighten fasteners 1-16 90 degrees.
    • Stage 4: Tighten fasteners 17-22 to 25 N.m (2.5 kgf.m , 18 ft.lbf).
      Fig 9: Lower Cylinder Block Bolt/Stud Tightening Sequence
      G01151935Courtesy of MAZDA MOTORS CORP.
  12. Using the special tool, measure the crankshaft end play. Refer to CAMSHAFT - END PLAY .
    Fig 10: Measuring Crankshaft End Play
    G01151936Courtesy of MAZDA MOTORS CORP.
  13. Using the special tool, install the crankshaft rear oil seal.
    Fig 11: Installing Crankshaft Rear Oil Seal
    G01151937Courtesy of MAZDA MOTORS CORP.
  14. Position the flexplate and install the bolts.
    Fig 12: Installing Flexplate
    G01151938Courtesy of MAZDA MOTORS CORP.
  15. Mount the engine on an engine stand.
  16. Apply SAE 5W-20 motor oil to the cylinder bores.
  17. Using the special tools, install the piston and connecting rod assemblies.
    Fig 13: Installing Piston & Connecting Rod Assemblies
    G01151939Courtesy of MAZDA MOTORS CORP.
  18. Check connecting rod bearing clearance. Refer to CONNECTING ROD - BEARING JOURNAL CLEARANCE .
  19. Install the connecting rod caps and bolts.
    • Tighten the bolts in two stages.
    • Stage 1: Tighten to 23 N.m (2.3 kgf.m, 17 ft.lbf).
    • Stage 2: Tighten to 43 N.m (4.4 kgf.m, 32 ft.lbf).
      Fig 14: Installing Connecting Rod Caps & Bolts
      G01151940Courtesy of MAZDA MOTORS CORP.
  20. Position the oil pump and install the bolts in the indicated sequence.
    Fig 15: Oil Pump Bolt Tightening Sequence
    G01151941Courtesy of MAZDA MOTORS CORP.
  21. Position the oil pan baffle and install the nuts.
    • Tighten the nuts in two stages.
    • Stage 1: Tighten to 5 N.m (0.5 kgf.m, 44 in. lbf).
    • Stage 2: Tighten 45 degrees.
    Fig 16: Installing Oil Pan Baffle
    G01151942Courtesy of MAZDA MOTORS CORP.
  22. Install a new O-ring seal on the oil pump screen and pick-up tube.
    Fig 17: Installing O-ring Seal
    G01151943Courtesy of MAZDA MOTORS CORP.
  23. Install the oil pump screen and pick up tube.
    1. Position the oil pump screen and pick up tube.
    2. Install the bolts.
    3. Install the nut.
      • Tighten the nut in two stages.
      • Stage 1: Tighten to 5 N.m (0.5 kgf.m , 44 in. lbf).
      • Stage 2: Tighten 45 degrees.
        Fig 18: Installing Oil Pump Screen & Pick Up Tube
        G01151944Courtesy of MAZDA MOTORS CORP.
  24. Install the power steering/engine support bracket.
    Fig 19: Installing Power Steering/Engine Support Bracket
    G01151945Courtesy of MAZDA MOTORS CORP.
  25. Install the oil separator.
    • Install the two bolts.
      Fig 20: Installing Oil Separator
      G01151946Courtesy of MAZDA MOTORS CORP.
    26. NOTE: LH shown, RH similar.
  26. Position the LH and RH cylinder heads, gaskets, and install the bolts.
    • Tighten the bolts in the sequence shown in six stages.
    • Stage 1: Tighten to 40 N.m (4.1 kgf.m, 30 ft.lbf).
    • Stage 2: Tighten to 90 N.m (9.2 kgf.m, 66 ft.lbf).
    • Stage 3: Loosen one full turn.
    • Stage 4: Tighten to 40 N.m (4.1 kgf.m , 30 ft.lbf).
    • Stage 5: Tighten 90 degrees.
    • Stage 6: Tighten 90 degrees.
      Fig 21: Cylinder Heads Bolt Tightening Sequence
      G01151947Courtesy of MAZDA MOTORS CORP.
  27. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position to locate Top Dead Center (TDC).
    Fig 22: Installing Crankshaft Damper Bolt
    G01151948Courtesy of MAZDA MOTORS CORP.
  28. Apply SAE 5W-20 motor oil to the LH and RH camshaft followers.
    29. CAUTION: The camshaft followers must be installed in the original position.
    NOTE: RH shown, LH similar.
    Fig 23: Installing Camshaft Followers
    G01151949Courtesy of MAZDA MOTORS CORP.
  29. Install the LH and RH camshaft followers.
  30. Apply SAE 5W-20 motor oil to the LH and RH camshafts.
  31. Install the LH and RH camshafts.
    • Locate the camshafts as shown.
      Fig 24: Installing Camshafts
      G01151950Courtesy of MAZDA MOTORS CORP.
    32. CAUTION: Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions.
    Fig 25: LH Camshaft Cap Bolt Tightening Sequence
    G01151951Courtesy of MAZDA MOTORS CORP.
  32. Position the LH camshaft caps and install the bolts in the sequence shown.
  33. Position the RH camshaft caps and install the bolts in the sequence shown.
    Fig 26: RH Camshaft Cap Bolt Tightening Sequence
    G01151952Courtesy of MAZDA MOTORS CORP.
  34. Remove the crankshaft damper bolt.
    Fig 27: Removing Crankshaft Damper Bolt
    G01151953Courtesy of MAZDA MOTORS CORP.
  35. Install the crankshaft sprockets.
    Fig 28: Installing Crankshaft Sprockets
    G01151954Courtesy of MAZDA MOTORS CORP.
    36. NOTE: LH shown, RH similar.
    Fig 29: Positioning Chain Tensioner In Soft-Jawed Vise
    G01151955Courtesy of MAZDA MOTORS CORP.
  36. Position the chain tensioner in a soft-jawed vise.
    37. NOTE: LH shown, RH similar.
    Fig 30: Holding Chain Tensioner Ratchet Lock Mechanism
    G01151956Courtesy of MAZDA MOTORS CORP.
  37. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
    38. CAUTION: During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
  38. Slowly compress the timing chain tensioner.
  39. Retain the tensioner piston with a 1.5 mm (0.06 in) wire or paper clip.
    Fig 31: Retaining Tensioner Piston
    G01151957Courtesy of MAZDA MOTORS CORP.
  40. If timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and RH timing chains.
    1. Mark any link to use as the crankshaft timing mark.
    2. Count 29 links counterclockwise from the crankshaft timing mark (including the starting link) and mark this link as the (LH chain Exhaust/RH chain Intake) cam sprocket timing mark.
    3. Continue counting counterclockwise to 42 and mark this link as the (LH chain Exhaust/RH chain Intake) sprocket timing mark
    Fig 32: Identifying Timing Marks On Timing Chains
    G01151958Courtesy of MAZDA MOTORS CORP.
  41. Position the guide and install the bolts.
    Fig 33: Installing Timing Chain Guide
    G01151959Courtesy of MAZDA MOTORS CORP.
  42. Install the LH timing chain.
    1. Position number one on the crankshaft.
    2. Count twenty-nine links from the number one link. Position on the exhaust cam sprocket.
    3. Continue counting to forty-two and position link on intake sprocket timing mark.
    Fig 34: Installing Timing Chain
    G01151960Courtesy of MAZDA MOTORS CORP.
  43. Install the LH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
      Fig 35: Installing Timing Chain & Tensioner Arm
      G01151961Courtesy of MAZDA MOTORS CORP.
  44. Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o'clock position.
    Fig 36: Crankshaft Keyway To 3 O'clock Position
    G01151962Courtesy of MAZDA MOTORS CORP.
  45. Verify that the RH camshafts are correctly positioned.
    Fig 37: RH Camshafts In Correct Position
    G01151963Courtesy of MAZDA MOTORS CORP.
  46. Install the RH timing chain.
    • Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.
      Fig 38: Installing RH Timing Chain
      G01151964Courtesy of MAZDA MOTORS CORP.
  47. Install the RH timing chain guide and install the bolts.
    Fig 39: Installing RH Timing Chain Guide
    G01151965Courtesy of MAZDA MOTORS CORP.
  48. Install the RH timing chain tensioner and tensioner arm.
    1. Install the tensioner arm.
    2. Position the tensioner.
    3. Install the bolts.
      4. Fig 40: Installing RH Timing Chain Tensioner &D Tensioner Arm
      G01151966Courtesy of MAZDA MOTORS CORP.
  49. Remove the LH and RH timing chain tensioner piston retaining wires.
  50. Remove the crankshaft damper bolt.
    Fig 41: Removing Crankshaft Damper Bolt
    G01151967Courtesy of MAZDA MOTORS CORP.
  51. Verify the timing with the following steps.
    1. There should be 12 chain links between the front camshaft timing marks.
    2. There should be 27 chain links between the camshaft and crankshaft timing marks.
    3. There should be 30 chain links between the camshaft and crankshaft timing marks.
      Fig 42: Verify Timing
      G01151968Courtesy of MAZDA MOTORS CORP.
    52. CAUTION: This pulse wheel is used in several different engines. Install the pulse wheel with the keyway in the slot stamped 20-25-34Y-30M (Color Blue).
    Fig 43: Installing Ignition Pulse Wheel
    G01151969Courtesy of MAZDA MOTORS CORP.
  52. Install the ignition pulse wheel.
  53. Install the special tool to hold the flexplate.
    Fig 44: Installing Special Tool
    G01151970Courtesy of MAZDA MOTORS CORP.
  54. Install three gaskets in the front cover.
    55. NOTE: The front cover must be installed and the bolts tightened within six minutes of sealant application.
    Fig 45: Applying Silicone Gasket & Sealant To Cylinder Block-To-Lower Cylinder Block & Cylinder Head Mating Surfaces
    G01151971Courtesy of MAZDA MOTORS CORP.
  55. Apply a 6 mm (0.24 in) dot of silicone gasket and sealant to the cylinder block to lower cylinder block and cylinder head mating surfaces.
    56. NOTE: Fasteners No. 1, 3, 4, 8, 10, 11, 14, 15 and 16 are studs.
    Fig 46: Front Cover Bolt/Stud Tightening Sequence
    G01151972Courtesy of MAZDA MOTORS CORP.
  56. Position the front cover and install the bolts and studs in the sequence shown.
  57. Using the special tool, install the crankshaft front oil seal.
    Fig 47: Installing Crankshaft Front Oil Seal
    G01151973Courtesy of MAZDA MOTORS CORP.
    58. NOTE: The oil pan must be installed and the bolts tightened within six minutes of sealant application.
    Fig 48: Applying Silicone Gasket & Sealant To Front Cover-To-Cylinder Block Mating Surface
    G01151974Courtesy of MAZDA MOTORS CORP.
  58. Apply a 10 mm (0.39 in) dot of silicone gasket and sealant to the front cover to cylinder block mating surface.
  59. Position the oil pan and gasket and loosely install the bolts and studs in the indicated sequence.
    Fig 49: Oil Pan Bolt/Stud Installation Sequence
    G01151975Courtesy of MAZDA MOTORS CORP.
  60. Align the transaxle face of the oil pan with the rear of the cylinder block. The pan should be 0.00 mm (0.0 in)-0.25 mm (0.009 in) under flush. Assemblies that are between 0.26 (0.01 in) -0.50 mm (0.019 in) should be shimmed using either one or two 0.25 mm (0.009 in) gold shims. Assemblies that are between 0.51 mm (0.20 in) -0.75 mm (0.029 in) should be shimmed using either one or two 0.50 mm (0.019 in) silver shims. If the pan measures greater than 0.75 mm (0.029 in) or the pan is over flush of the cylinder block, the entire pan assembly must be removed and a new one installed.
  61. Tighten the oil pan bolts and studs in the sequence shown.
    Fig 50: Oil Pan Bolt Tightening Sequence
    G01151976Courtesy of MAZDA MOTORS CORP.
  62. Install a new seal on the oil level indicator tube.
    Fig 51: Installing Seal On Oil Level Indicator Tube
    G01151977Courtesy of MAZDA MOTORS CORP.
  63. Install the oil level indicator tube and install the bolt.
    Fig 52: Installing Oil Level Indicator Tube
    G01151978Courtesy of MAZDA MOTORS CORP.
    64. NOTE: The crankshaft damper must be installed and the bolt tightened with in six minutes of sealant application.
    Fig 53: Applying Silicone Gasket & Sealant
    G01151979Courtesy of MAZDA MOTORS CORP.
  64. Apply silicone gasket and sealant to the end of the crankshaft damper keyway slot.
  65. Using the special tool, install the crankshaft vibration damper.
    Fig 54: Installing Crankshaft Vibration Damper
    G01151980Courtesy of MAZDA MOTORS CORP.
  66. Install the crankshaft vibration damper washer and bolt.
    • Tighten the bolt in four stages.
    • Stage 1: Tighten to 120 N.m (1.22 kgf.m , 89 ft.lbf).
    • Stage 2: Loosen one full turn (360 degrees).
    • Stage 3: Tighten to 50 N.m (5.1 kgf.m , 37 ft.lbf).
    • Stage 4: Tighten to 90 N.m (9.2 kgf.m , 66 ft.lbf).
    Fig 55: Installing Crankshaft Vibration Damper Washer & Bolt
    G01151981Courtesy of MAZDA MOTORS CORP.
  67. Install new gaskets in the valve covers.
    68. NOTE: The valve cover must be installed and the bolts and studs tightened with in six minutes of sealant application.
    NOTE: LH shown, RH similar.
    Fig 56: Applying Silicone Gasket & Sealant At Cylinder Block-To-Front Cover Mating Surface Of Valve Covers
    G01151982Courtesy of MAZDA MOTORS CORP.
  68. Apply a 8 mm (0.31 in) dot of silicone gasket and sealant at the cylinder block to front cover mating surface of the LH and RH valve covers.
  69. Position the RH valve cover and install the bolts and studs in the sequence shown.
    Fig 57: RH Valve Cover Bolt Tightening Sequence
    G01151983Courtesy of MAZDA MOTORS CORP.
  70. Position the LH valve cover and install the bolts and studs in the sequence shown.
    Fig 58: LH Valve Cover Bolt Tightening Sequence
    G01151984Courtesy of MAZDA MOTORS CORP.
    71. NOTE: RH shown, LH similar.
    Fig 59: Installing Spark Plugs
    G01151985Courtesy of MAZDA MOTORS CORP.
  71. Install the spark plugs.
    72. NOTE: RH shown, LH similar.
    NOTE: Apply a light film of silicone brake caliper grease and dielectric compound to the interior of the spark plug boot prior to installation.
    Fig 60: Installing Coil-On-Plugs & Install Bolts
    G01151986Courtesy of MAZDA MOTORS CORP.
  72. Install the six coil-on-plugs and install the bolts.
  73. Position the knock sensor and install the bolt.
    Fig 61: Installing Knock Sensor
    G01151987Courtesy of MAZDA MOTORS CORP.
  74. Remove the special tool.
    Fig 62: Removing Special Tool
    G01151988Courtesy of MAZDA MOTORS CORP.
  75. Position the coolant bypass tube and connect the hoses.
    Fig 63: Installing Coolant Bypass Tube & Hoses
    G01151989Courtesy of MAZDA MOTORS CORP.
  76. Install the oil pressure sender and the block heater.
    Fig 64: Installing Oil Pressure Sender & Block Heater
    G01151990Courtesy of MAZDA MOTORS CORP.
  77. Install the oil cooler.
    Fig 65: Installing Oil Cooler
    G01151991Courtesy of MAZDA MOTORS CORP.
  78. Install the radio ignition noise suppressor electrical connector.
    Fig 66: Installing Radio Ignition Noise Suppressor Electrical Connector
    G01151992Courtesy of MAZDA MOTORS CORP.
  79. Install the generator support bracket.
    Fig 67: Installing Generator Support Bracket
    G01151993Courtesy of MAZDA MOTORS CORP.
  80. Install the power steering pump.
    Fig 68: Installing Power Steering Pump
    G01151994Courtesy of MAZDA MOTORS CORP.
  81. Install the power steering pump pulley.
    Fig 69: Installing Power Steering Pump Pulley
    G01151995Courtesy of MAZDA MOTORS CORP.
  82. Install the oil filter.
    Fig 70: Installing Oil Filter
    G01151996Courtesy of MAZDA MOTORS CORP.
  83. Connect the coolant hoses at the oil cooler.
    Fig 71: Installing Coolant Hoses At Oil Cooler
    G01151997Courtesy of MAZDA MOTORS CORP.
  84. Install the water pump assembly.
    Fig 72: Installing Water Pump Assembly
    G01151998Courtesy of MAZDA MOTORS CORP.
  85. Position a new gasket and tighten the LH exhaust manifold nuts in the sequence shown.
    Fig 73: LH Exhaust Manifold Nut Tightening Sequence
    G01151999Courtesy of MAZDA MOTORS CORP.
  86. Install the engine lift bracket.
    Fig 74: Installing Engine Lift Bracket
    G01152000Courtesy of MAZDA MOTORS CORP.
  87. Position the gasket and install the lower intake manifold.
    Fig 75: Installing Lower Intake Manifold
    G01152001Courtesy of MAZDA MOTORS CORP.
  88. Position and connect the engine control sensor wiring to the following components:
    • Coils on plugs.
    • Fuel injectors.
    Fig 76: Connecting Engine Control Sensor Wiring
    G01152002Courtesy of MAZDA MOTORS CORP.
  89. Connect the radio interference capacitor.
    Fig 77: Connecting Radio Interference Capacitor
    G01152003Courtesy of MAZDA MOTORS CORP.
  90. Connect the crankshaft and camshaft position sensor electrical connectors.
    Fig 78: Connecting Crankshaft & Camshaft Position Sensor Electrical Connectors
    G01152004Courtesy of MAZDA MOTORS CORP.
  91. Install new gaskets in the upper intake manifold.
  92. Install the upper intake manifold.
    Fig 79: Upper Intake Manifold Bolt Tightening Sequence
    G01152005Courtesy of MAZDA MOTORS CORP.
  93. Install and connect the engine control wire harness.
    Fig 80: Installing Engine Control Wire Harness
    G01152006Courtesy of MAZDA MOTORS CORP.
  94. Connect the coolant temperature sender and the oil pressure switch.
    Fig 81: Connecting Coolant Temperature Sender & Oil Pressure Switch
    G01152007Courtesy of MAZDA MOTORS CORP.
  95. Connect the vacuum line to the fuel pressure damper.
    Fig 82: Connecting Vacuum Line To Fuel Pressure Damper
    G01152008Courtesy of MAZDA MOTORS CORP.
  96. Connect the engine control sensor wiring to the upper intake manifold.
    Fig 83: Connecting Engine Control Sensor Wiring To Upper Intake Manifold
    G01152009Courtesy of MAZDA MOTORS CORP.
  97. Connect the EGR vacuum regulator and the differential pressure feedback EGR electrical connectors.
    Fig 84: Connecting EGR Vacuum Regulator & Differential Pressure Feedback EGR Electrical Connectors
    G01152010Courtesy of MAZDA MOTORS CORP.
  98. Install the PCV tube.
    Fig 85: Installing PCV Tube
    G01152011Courtesy of MAZDA MOTORS CORP.
  99. Connect the Idle Air Control (IAC) valve and the Throttle Position (TP) sensor electrical connectors.
    Fig 86: Connecting IAC Valve & TP Sensor Electrical Connectors
    G01152012Courtesy of MAZDA MOTORS CORP.
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