Engine Mechanical - 3.0L: Engine: Disassembly

Separate the engine control sensor wiring connectors from the upper intake manifold.

Fig 1: Separating Engine Control Sensor Wiring Connectors From Upper Intake Manifold
Courtesy of MAZDA MOTORS CORP.
Disconnect the idle air control valve and the throttle position sensor.

Fig 2: Disconnecting Idle Air Control Valve & Throttle Position Sensor
Courtesy of MAZDA MOTORS CORP.
Disconnect the Exhaust Gas Recirculation (EGR) vacuum regulator and the differential pressure feedback EGR electrical connectors.

Fig 3: Disconnecting EGR Vacuum Regulator & Differential Pressure Feedback EGR Electrical Connectors
Courtesy of MAZDA MOTORS CORP.
Remove the Positive Crankcase Ventilation (PCV) tube.

Fig 4: Removing PCV Tube
Courtesy of MAZDA MOTORS CORP.
Disconnect the vacuum line from the fuel pressure regulator.

Fig 5: Disconnecting Fuel Pressure Regulator Vacuum Line
Courtesy of MAZDA MOTORS CORP.
Disconnect and remove the engine control wire harness.

Fig 6: Removing Engine Control Wire Harness
Courtesy of MAZDA MOTORS CORP.
Remove the bolts and upper intake manifold.

Fig 7: Removing Upper Intake Manifold
Courtesy of MAZDA MOTORS CORP.
Disconnect the crankshaft and camshaft position sensors.

Fig 8: Disconnecting Crankshaft & Camshaft Position Sensors
Courtesy of MAZDA MOTORS CORP.
Disconnect the radio ignition interference capacitor.

Fig 9: Disconnecting Radio Ignition Interference Capacitor
Courtesy of MAZDA MOTORS CORP.
Disconnect the remaining electrical connectors and harness retainers and remove the harness.
- Coils-on-plugs.
- Fuel injectors.
Fig 10: Disconnecting Electrical Connectors & Harness Retainers
Courtesy of MAZDA MOTORS CORP.
Remove the bolts and the six coil-on-plugs.

Fig 11: Removing Coil-On-Plugs
Courtesy of MAZDA MOTORS CORP.
Disconnect the coolant temperature sensor and the oil pressure switch.

Fig 12: Disconnecting Coolant Temperature Sensor & Oil Pressure Switch
Courtesy of MAZDA MOTORS CORP.
Remove the fuel charging wire harness.

Fig 13: Removing Fuel Charging Wire Harness
Courtesy of MAZDA MOTORS CORP.
Remove the lower intake manifold.

Fig 14: Removing Lower Intake Manifold
Courtesy of MAZDA MOTORS CORP.
Remove the radio interference capacitor.
- Remove the nut.
Fig 15: Removing Radio Interference Capacitor
Courtesy of MAZDA MOTORS CORP.
Remove the RH valve cover.
- Remove and discard the gasket if damaged.
Remove the engine lift bracket.

Fig 16: Removing Engine Lift Bracket
Courtesy of MAZDA MOTORS CORP.
Remove the LH exhaust manifold.

Fig 17: Removing LH Exhaust Manifold
Courtesy of MAZDA MOTORS CORP.
Remove the knock sensor.

Fig 18: Removing Knock Sensor
Courtesy of MAZDA MOTORS CORP.
Remove the LH valve cover.
- Remove and discard the gasket if damaged.
  
  Fig 19: Removing LH Valve Cover
  Courtesy of MAZDA MOTORS CORP.
Disconnect the hoses.

Fig 20: Disconnecting Hoses
Courtesy of MAZDA MOTORS CORP.
Remove the water pump assembly.

Fig 21: Removing Water Pump Assembly
Courtesy of MAZDA MOTORS CORP.
Disconnect the coolant hoses at the oil cooler.

Fig 22: Disconnecting Coolant Hoses At Oil Cooler
Courtesy of MAZDA MOTORS CORP.
Remove the bolt.

Fig 23: Removing Bolt
Courtesy of MAZDA MOTORS CORP.
Using the special tool, remove the crankshaft damper.

Fig 24: Removing Crankshaft Damper
Courtesy of MAZDA MOTORS CORP.
Remove the power steering pump pulley.

Fig 25: Removing Power Steering Pump Pulley
Courtesy of MAZDA MOTORS CORP.
Remove the oil filter.

Fig 26: Removing Oil Filter
Courtesy of MAZDA MOTORS CORP.
Remove the power steering pump.

Fig 27: Removing Power Steering Pump
Courtesy of MAZDA MOTORS CORP.
Remove the generator support bracket.

Fig 28: Removing Generator Support Bracket
Courtesy of MAZDA MOTORS CORP.
Remove the oil cooler.

Fig 29: Removing Oil Cooler
Courtesy of MAZDA MOTORS CORP.
Remove the oil pressure sender and the block heater.

Fig 30: Removing Oil Pressure Sender & Block Heater
Courtesy of MAZDA MOTORS CORP.
Remove the bolts and studs and the oil pan.
- Discard the gasket.
  
  Fig 31: Removing Oil Pan
  Courtesy of MAZDA MOTORS CORP.
Remove the bolts, nut and the oil pick up tube and screen.

Fig 32: Removing Oil Pick Up Tube & Screen
Courtesy of MAZDA MOTORS CORP.
Remove the nuts and the oil pan baffle.

Fig 33: Removing
Courtesy of MAZDA MOTORS CORP.
Remove the stud and the oil level indicator and tube.

Fig 34: Removing Oil Level Indicator & Tube
Courtesy of MAZDA MOTORS CORP.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surface. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.

Clean all sealing surfaces with metal surface cleaner.

Remove the bolts, studs, and the front cover.
- Discard the gasket.
Remove the crankshaft front seal from the front cover.

Fig 36: Removing Crankshaft Front Seal
Courtesy of MAZDA MOTORS CORP.

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 37: Removing Ignition Pulse Wheel

G01151875

Courtesy of MAZDA MOTORS CORP.

Remove the ignition pulse wheel.
Install the damper bolt.

Fig 38: Installing Damper Bolt
Courtesy of MAZDA MOTORS CORP.

NOTE: RH shown, LH similar.

Fig 39: Removing Spark Plugs

G01151877

Courtesy of MAZDA MOTORS CORP.

Remove the LH and RH spark plugs.
Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at Top Dead Center (TDC).
- Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.
Fig 40: Positioning Crankshaft Keyway In 11 O'clock Position
Courtesy of MAZDA MOTORS CORP.
Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the RH camshafts in the neutral position.

Fig 41: Positioning Crankshaft Keyway In 3 O'clock Position
Courtesy of MAZDA MOTORS CORP.
Verify that the RH camshafts are correctly positioned.

Fig 42: Verifying RH Camshafts Are Correctly Positioned
Courtesy of MAZDA MOTORS CORP.
Remove the RH timing chain tensioner arm.
1. Remove the bolts.
2. Remove the tensioner.
3. Remove the tensioner arm.
  
  Fig 43: Removing RH Timing Chain Tensioner Arm
  Courtesy of MAZDA MOTORS CORP.
Remove the bolts, RH timing chain guide and the timing chain.

Fig 44: Removing RH Timing Chain Guide & Timing Chain
Courtesy of MAZDA MOTORS CORP.
Rotate the crankshaft clockwise 600 degrees (1-2/3 times) to position the crankshaft keyway in the 11 o'clock position. This will position the LH camshafts in the neutral position.

Fig 45: Positioning Crankshaft Keyway In 11 O'clock Position
Courtesy of MAZDA MOTORS CORP.
Verify that the LH camshafts are in the neutral position.

Fig 46: Verifying LH Camshafts In Neutral Position
Courtesy of MAZDA MOTORS CORP.
Remove the LH timing chain and tensioner arm.
1. Remove the bolts.
2. Remove the tensioner.
3. Remove the tensioner arm.
  
  Fig 47: Removing LH Timing Chain & Tensioner Arm
  Courtesy of MAZDA MOTORS CORP.
Remove the LH timing chain and timing chain guide.

Fig 48: Removing LH Timing Chain & Timing Chain Guide
Courtesy of MAZDA MOTORS CORP.
Remove the damper bolt and the crankshaft sprockets.

Fig 49: Removing Damper Bolt & Crankshaft Sprockets
Courtesy of MAZDA MOTORS CORP.

NOTE: RH shown, LH similar.

NOTE: The camshaft caps have alignment dowels.

Fig 50: Camshaft Cap Bolt Loosening Sequence

G01151888

Courtesy of MAZDA MOTORS CORP.

Loosen the LH and RH camshaft cap bolts in the indicated sequence and remove the camshaft caps.
- Tap the caps lightly with a soft-faced mallet to loosen the camshaft caps.
Remove the LH and RH camshafts.

Fig 51: Removing Camshafts
Courtesy of MAZDA MOTORS CORP.

CAUTION: The camshaft followers must be installed in the original position.

NOTE: RH shown, LH similar.

Remove the LH and RH camshaft followers.
- Mark the location of the followers using a permanent-type marker.
Remove the coolant bypass tube.

Fig 52: Removing Coolant Bypass Tube
Courtesy of MAZDA MOTORS CORP.

NOTE: RH shown, LH similar.

Loosen the bolts in the indicated sequence and remove the LH and RH cylinder heads.
- Discard the gaskets.
  
  Fig 53: Cylinder Head Bolt Loosening Sequence
  Courtesy of MAZDA MOTORS CORP.
Remove the power steering/engine support bracket.

Fig 54: Removing Power Steering/Engine Support Bracket
Courtesy of MAZDA MOTORS CORP.
Remove the oil separator.

Fig 55: Removing Oil Separator
Courtesy of MAZDA MOTORS CORP.
Remove the bolts in the indicated sequence and remove the oil pump.

Fig 56: Oil Pump Bolt Removal Sequence
Courtesy of MAZDA MOTORS CORP.
Using the special tool, remove the cylinder ridge.

Fig 57: Removing Cylinder Ridge
Courtesy of MAZDA MOTORS CORP.
Remove the connecting rod cap bolts. Hold the piston/rod assembly to keep it from falling from the engine block.

Fig 58: Removing Connecting Rod Cap Bolts
Courtesy of MAZDA MOTORS CORP.
Using the special tool, remove the piston/rod assembly from the engine block.

Fig 59: Removing Piston/Rod Assembly
Courtesy of MAZDA MOTORS CORP.
Remove the engine block from the stand and place it on a workbench.
Remove the bolts and the flexplate.

Fig 60: Removing Flexplate
Courtesy of MAZDA MOTORS CORP.
Remove the bolts and studs in the indicated sequence and remove the lower cylinder block.

Fig 61: Lower Cylinder Block Bolt Removal Sequence
Courtesy of MAZDA MOTORS CORP.
Remove the crankshaft rear main seal and remove the crankshaft.

Fig 62: Removing Crankshaft Rear Main Seal
Courtesy of MAZDA MOTORS CORP.
Remove the crankshaft key.

Fig 63: Removing Crankshaft Key
Courtesy of MAZDA MOTORS CORP.
Remove the crankshaft thrust bearing from the cylinder block.

Fig 64: Removing Crankshaft Thrust Bearing
Courtesy of MAZDA MOTORS CORP.
Remove the bearings from the lower cylinder block.

Fig 65: Removing Bearings From Lower Cylinder Block
Courtesy of MAZDA MOTORS CORP.
Remove the crankshaft main bearings from the cylinder block.

Fig 66: Removing Bearings From Cylinder Block
Courtesy of MAZDA MOTORS CORP.
Inspect the cylinder block, lower cylinder block, cylinder heads, pistons and connecting rods.