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Timing Chain Removal/Installation - 4.0L

  1. Remove the valve covers. See VALVE COVER - RH REMOVAL/INSTALLATION - 4.0L  and VALVE COVER - LH REMOVAL/INSTALLATION - 4.0L .
  2. Remove the intake manifold. See INTAKE MANIFOLD REMOVAL/INSTALLATION - 4.0L .
  3. Remove the fuel supply manifold. See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL/INSTALLATION .
  4. Remove the accessory drive belt. See DRIVE BELT REMOVAL/INSTALLATION - 4.0L .
  5. Remove the thermostat housing. See THERMOSTAT REMOVAL/INSTALLATION - 4.0L .
  6. Remove the valve tappets. See VALVE TAPPET REMOVAL/INSTALLATION - 4.0L .
    NOTE:
    • You must re-time the LH and RH camshafts when either camshaft is disturbed.
  7. Turn the crankshaft clockwise to position the number one cylinder at TDC using the special tool.
    NOTE:
    • The special tool must be installed on the damper and should contact the engine block, this positions the engine at top dead center (TDC).
    Fig 1: Installing Special Tool
    G03728568Courtesy of MAZDA MOTORS CORP.
  8. Install the special tool with the adapter 303-575 or equivalent.
    CAUTION:
    • The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
  9. Using the special tool, loosen the RH camshaft sprocket bolt.
    Fig 2: Loosening RH Camshaft Sprocket Bolt
    G03728569Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The camshaft timing slots are off-center.
  10. Position the camshaft timing slots below the center-line of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.
  11. Raise and support the vehicle. See LIFTING .
  12. Remove the RH wheel and tire.
  13. Remove the RH lower splash shield.
    Fig 3: Removing RH Lower Splash Shield
    G03728570Courtesy of MAZDA MOTORS CORP.
  14. Remove the RH camshaft tensioner.
    Fig 4: Removing RH Camshaft Tensioner
    G03728571Courtesy of MAZDA MOTORS CORP.
  15. Lower the vehicle.
    NOTE:
    • Leave the top two special tool clamp bolts loose.
  16. Install the special tools on the rear of the RH cylinder head.
    Fig 5: Installing Special Tools On Rear Of RH Cylinder Head
    G03728572Courtesy of MAZDA MOTORS CORP.
  17. Install the RH camshaft chain tensioner, but do not tighten.
    Fig 6: Installing RH Camshaft Chain Tensioner
    G03728573Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
  18. Tighten the bolts.
    1. Tighten the top of two clamp bolts of the special tool to 10 N.m (89 lb-in).
    2. Tighten the camshaft bolt.
      Fig 7: Tightening Bolts - With Torque Specification
      G03728574Courtesy of MAZDA MOTORS CORP.
  19. Tighten the RH camshaft tensioner.
    Fig 8: Tightening RH Camshaft Tensioner - With Torque Specification
    G03728575Courtesy of MAZDA MOTORS CORP.
  20. Raise the vehicle.
  21. Install the RH lower splash shield.
    Fig 9: Installing RH Lower Splash Shield
    G03728576Courtesy of MAZDA MOTORS CORP.
  22. Install the RH wheel and tire.
  23. Lower the vehicle.
  24. Remove the special tools from the RH cylinder head.
  25. Remove the LH camshaft tensioner.
    Fig 10: Removing LH Camshaft Tensioner
    G03728577Courtesy of MAZDA MOTORS CORP.
  26. Install the special tools on the front of the LH cylinder head and tighten the top two clamp bolts to 10 N.m (89 lb-in).
    Fig 11: Installing Special Tools On Front Of LH Cylinder Head
    G03728578Courtesy of MAZDA MOTORS CORP.
  27. Loosen the LH camshaft sprocket bolt.
    Fig 12: Loosening LH Camshaft Sprocket Bolt
    G03728579Courtesy of MAZDA MOTORS CORP.
  28. Loosen the top two clamp bolts on the special tool to allow the camshaft sprocket to rotate freely.
    NOTE:
    • The camshaft timing slots are off-center.
  29. Position the camshaft timing slots below the center-line of the camshaft to correctly fit the special tools, and install the special tools on the rear of the LH cylinder head.
    Fig 13: Installing Special Tools On Rear Of LH Cylinder Head
    G03728580Courtesy of MAZDA MOTORS CORP.
  30. Install the LH camshaft chain tensioner, but do not tighten.
    Fig 14: Installing LH Camshaft Chain Tensioner
    G03728581Courtesy of MAZDA MOTORS CORP.
  31. Tighten the bolts.
    1. Tighten the top two clamp bolts of the special tool to 10 N.m (89 lb-in).
    2. Tighten the camshaft bolt.
      Fig 15: Tightening Bolts - With Torque Specification
      G03728582Courtesy of MAZDA MOTORS CORP.
  32. Tighten the LH camshaft tensioner.
    Fig 16: Tightening LH Camshaft Tensioner - With Torque Specification
    G03728583Courtesy of MAZDA MOTORS CORP.
  33. Remove all of the special tools.
  34. Install the valve tappets. See VALVE TAPPET REMOVAL/INSTALLATION - 4.0L .
  35. Install the thermostat housing. See THERMOSTAT REMOVAL/INSTALLATION - 4.0L .
  36. Install the accessory drive belt. See DRIVE BELT REMOVAL/INSTALLATION - 4.0L .
  37. Install the fuel supply manifold. See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL/INSTALLATION .
  38. Install the intake manifold. See INTAKE MANIFOLD REMOVAL/INSTALLATION - 4.0L .
  39. Install the valve covers. See VALVE COVER - RH REMOVAL/INSTALLATION - 4.0L  and VALVE COVER - LH REMOVAL/INSTALLATION - 4.0L .
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