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Valve Clearance Adjustment

WARNING: This page is about a different car, the 2004 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  2. Remove the tire (RH).
  3. Remove the splash shield (RH).
  4. Remove the plug hole plate.

    (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)

  5. Remove the high-tension lead. (See HIGH-TENSION LEAD (L3) REMOVAL/INSTALLATION .)
  6. Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION .)
  7. Remove the oil control valve (OCV) connector.
  8. Remove the ventilation hose.
  9. Remove the cylinder head cover.
  10. Remove the drive belt. (See DRIVE BELT REPLACEMENT .)
  11. Remove the front drive shaft (RH) from the joint shaft. (See REMOVAL & INSTALLATION .)
  12. Remove the engine front cover lower blind plug.
    Fig 1: Locating Engine Front Cover Lower Blind Plug
    G01024982Courtesy of MAZDA MOTORS CORP.
  13. Remove the engine front cover upper blind plug.
    Fig 2: Locating Engine Front Cover Upper Blind Plug
    G01024983Courtesy of MAZDA MOTORS CORP.
  14. Remove the cylinder block lower blind plug.
  15. Install the SST  as shown in the figure.
    Fig 3: Installing Special Service Tool In Place Of Cylinder Block Lower Blind Plug
    G01024984Courtesy of MAZDA MOTORS CORP.
  16. Rotate the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is contacting the SST  ).
  17. Loosen the timing chain.
    1. Unlock the chain tensioner ratchet using a suitable screwdriver or equivalent tool.
    2. Rotate the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen a timing chain.
    3. Placing the suitable bolt (M6 X 1.0 length 25-35 mm {0.99-1.37 in})  at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
    Fig 4: Unlocking Chain Tensioner Ratchet
    G01024985Courtesy of MAZDA MOTORS CORP.
  18. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
    Fig 5: Holding Exhaust Camshaft
    G01024986Courtesy of MAZDA MOTORS CORP.
  19. Remove the exhaust camshaft sprocket.
    Fig 6: Removing Exhaust Camshaft Sprocket
    G01024987Courtesy of MAZDA MOTORS CORP.
  20. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure.
    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 from where they were removed. Do not mix the caps.
    Fig 7: Removing Sequence Of Camshaft Cap Bolts
    G01024988Courtesy of MAZDA MOTORS CORP.
  21. Remove the camshaft.
  22. Remove the tappet.
  23. 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} 

  24. Install the camshaft and No.1 cylinder aligned with the TDC position.
  25. Tighten the camshaft cap bolt in the following two steps.
    1. Tighten to 5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.6 in.Ibf}. 
    2. Tighten to 14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf}. 
    Fig 8: Tightening Sequence Of Camshaft Cap Bolt
    G01024989Courtesy of MAZDA MOTORS CORP.
  26. Install the exhaust camshaft sprocket.
    NOTE:
    • Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.
    Fig 9: Installing Exhaust Camshaft Sprocket
    G01024990Courtesy of MAZDA MOTORS CORP.
  27. Install the SST  to the camshaft as shown in the figure.
    Fig 10: Installing Special Service Tool To Camshaft
    G01024991Courtesy of MAZDA MOTORS CORP.
  28. 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.
  29. Turn the crankshaft clockwise until the crankshaft is in the No.1 cylinder TDC position (until the balance weight is contacting to the SST  ).
  30. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
    Fig 11: Holding Exhaust Camshaft
    G01024992Courtesy of MAZDA MOTORS CORP.
  31. Tighten the exhaust camshaft sprocket lock bolt.

    Tightening torque 

    89-95 N.m {9.1-9.6 kgf.m, 65.7-70.0 ft.lbf} 

  32. Remove the SST  from the camshaft.
  33. Remove the SST  from the block lower blind plug.
  34. Rotate the crankshaft two times clockwise until the crankshaft is in the TDC position, reinstall the SSTs  to the camshaft and cylinder block, and inspect the valve timing.
    • If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step  16.
  35. Apply silicone sealant to the engine front cover upper blind plug.
  36. Install the 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 12: Installing Engine Front Cover Upper Blind Plug
    G01024993Courtesy of MAZDA MOTORS CORP.
  37. Install the cylinder block lower blind plug.

    Tightening torque 

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

    Fig 13: Install The Cylinder Block Lower
    G01024994Courtesy of MAZDA MOTORS CORP.
  38. Install the new engine front cover lower blind plug.

    Tightening torque 

    10.0-14.0 N.m {102.0-142.7 kgf.cm, 73.8-103.2 in.lbf} 

    Fig 14: Blind Plug Installing Engine Front Cover Lower Blind Plug
    G01024995Courtesy of MAZDA MOTORS CORP.
  39. Connect the front drive shaft (RH) and the joint shaft. (See REMOVAL & INSTALLATION .)
  40. Install the drive belt. (See DRIVE BELT REPLACEMENT .)
  41. Install the cylinder head cover. (See Cylinder Head Cover Installation Note .)
  42. Install the ventilation hose.
  43. Install the oil control valve (OCV) connector.
  44. Install the high-tension lead. (See HIGH-TENSION LEAD (L3) REMOVAL/INSTALLATION .)
  45. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION .)
  46. Install the plug hole plate.

    (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)

  47. Install the splash shield (RH).
  48. Install the tire (RH).
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