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WARNING: This page is about a different car, the 2005 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.

WARNING:

Failure to position the No. 1 piston at top dead center TDC can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
Remove the plug bolt.

Fig 1: Removing Plug Bolt
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Only turn the engine in the normal direction of rotation.
NOTE:
- Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
Install the special tool.

Fig 2: Installing Special Tool
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Clean the sealing surface with metal surface cleaner.
Install the oil pump assembly and bolts. Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 20 Nm (15 lb-ft).
  
  Fig 3: Installing Oil Pump Assembly Bolts In Sequence
  Courtesy of MAZDA MOTORS CORP.
  NOTE:
  - Clean the sealing surface with a metal surface cleaner.
Install a new oil pump pickup tube gasket and the pickup tube. Tighten the bolts in the sequence shown.

Fig 4: Installing New Oil Pump Pickup Tube Gasket And Pickup Tube - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Using the special tool, install the rear main oil seal.

Fig 5: Installing Rear Main Oil Seal
Courtesy of MAZDA MOTORS CORP.
Tighten the rear main oil seal bolts in the sequence shown.

Fig 6: Tightening Sequence Of Rear Main Oil Seal Bolts -- With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
NOTE:
- Clean the mating surface with metal surface cleaner.
NOTE:
- If the oil pan is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2.5-mm (0.1-in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Tighten the oil pan bolts in the sequence shown.

Fig 7: Tightening Sequence Of Oil Pan Bolts -- With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.

Fig 8: Identifying Cylinder Head Alignment Dowels
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Clean the gasket surface with metal surface cleaner.
Apply silicone gasket and sealant to the locations shown.

Fig 9: Applying Silicone Gasket And Sealant
Courtesy of MAZDA MOTORS CORP.
Install a new cylinder head gasket.
Clean the cylinder head gasket surface with metal surface cleaner.
NOTE:
- The cylinder head must be secured within four minutes of silicone gasket application. If the cylinder head is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
NOTE:
- The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
NOTE:
- Lubricate the cylinder head bolts with clean engine oil.
Install the cylinder head and the new bolts. Tighten the bolts in the sequence shown in five stages.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 15 Nm (11 lb-ft).
- Stage 3: Tighten to 45 Nm (33 lb-ft).
- Stage 4: Tighten an additional 90 degrees (1/4 turn).
- Stage 5: Tighten an additional 90 degrees (1/4 turn).
  
  Fig 10: Identifying Tightening Sequence Of Cylinder Head Bolts
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - Install the camshafts with the alignment slots in the camshaft lined up so the camshaft alignment plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the disassembly procedure. Rotating the camshafts, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
  NOTE:
  - Lubricate the camshaft journals and bearing caps with clean engine oil.
Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
- Stage 2: Tighten the bolts to 7 Nm (62 lb-in).
- Stage 3: Tighten the bolts to 16 Nm (12 lb-ft).
  
  Fig 11: Identifying Tightening Sequence Of Camshaft And Bearing Cap Bolts
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. The diamond washers must be installed correctly, or severe engine damage can result.
Install the washers and the oil pump chain and sprockets.
- The crankshaft sprocket flange must be facing away from the engine block.
  
  Fig 12: Installing Washer
  Courtesy of MAZDA MOTORS CORP.
NOTE:
- The oil pump chain sprocket must be held in place.
Tighten the oil pump sprocket bolt.

Fig 13: Tightening Oil Pump Sprocket Bolt - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the oil pump chain guide and the shoulder bolt.

Fig 14: Installing Oil Pump Chain Guide And Shoulder Bolt - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.

Fig 15: Installing Oil Pump Chain Tensioner - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Sprockets must turn freely on the camshafts.
Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.

Fig 16: Installing Camshaft Sprocket Bolts
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Do not compress the ratchet assembly. This will damage the ratchet assembly.
Using the edge of a vise, compress the timing chain tensioner plunger.

Fig 17: Compressing Timing Chain Tensioner Plunger
Courtesy of MAZDA MOTORS CORP.
Using a small pick, push back and hold the ratchet mechanism.

Fig 18: Pushing Back And Holding Ratchet Mechanism
Courtesy of MAZDA MOTORS CORP.
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Fig 19: Pushing Ratchet Arm Back Into Tensioner Housing
Courtesy of MAZDA MOTORS CORP.
Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Fig 20: Installing Paper Clip Into Hole In Tensioner Housing
Courtesy of MAZDA MOTORS CORP.
Install the timing chain.

Fig 21: Installing Timing Chain
Courtesy of MAZDA MOTORS CORP.
Install the timing chain guides.

Fig 22: Installing Timing Chain Guides - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.

Fig 23: Installing Timing Chain Tensioner - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
Install the special tool in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.

Fig 24: Installing Special Tool In Timing Slots On Rear Of Both Camshafts
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshafts in place.
Tighten the camshaft sprocket bolts.

Fig 25: Tightening Camshaft Sprocket Bolts - With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Clean the front cover gasket surface with metal surface cleaner.
Apply a 2.5-mm (0.1 -in) bead of silicone gasket and sealant to the front cover.

Fig 26: Applying Bead Of Silicone Gasket And Sealant To Front Cover
Courtesy of MAZDA MOTORS CORP.
Apply silicone gasket and sealant to the locations shown.

Fig 27: Applying Silicone Gasket And Sealant
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The front cover must be secured within four minutes of silicone gasket application. If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
Install the front cover. Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten the 8 mm bolts to 10 Nm (89 lb-in).
- Stage 2: Tighten the 10 mm bolts to 25 Nm (18 lb-ft).
- Stage 3: Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
Fig 28: Identifying Tightening Sequence Of Front Cover Bolts
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Do not reuse the crankshaft pulley bolt.
NOTE:
- Apply clean engine oil on the seal area before installing.
Install the crankshaft pulley and hand-tighten the bolt.

Fig 29: Installing Crankshaft Pulley Bolt
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Only hand-tighten the bolt or damage to the front cover can occur.
NOTE:
- This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6-mm (0.23-in) x 18-mm (0.7-in) bolt through the crankshaft pulley and thread it into the front cover.
- Rotate the crankshaft pulley as necessary to align the bolt holes.
  
  Fig 30: Installing Bolt Through Crankshaft Pulley
  Courtesy of MAZDA MOTORS CORP.
  CAUTION:
  - Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.
Using the special tools to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in two stages.
- Stage 1: Tighten to 100 Nm (74 lb-ft).
- Stage 2: Rotate an additional 90 degrees (1/4 turn).
  
  Fig 31: Tightening Crankshaft Pulley Bolt
  Courtesy of MAZDA MOTORS CORP.
Remove the special tools.

Fig 32: Removing Special Tools
Courtesy of MAZDA MOTORS CORP.
Remove the 6-mm (0.23-in) x 18-mm (0.7-in) bolt.

Fig 33: Removing Bolt
Courtesy of MAZDA MOTORS CORP.
Remove the special tool.

Fig 34: Removing Special Tool (1 Of 2)
Courtesy of MAZDA MOTORS CORP.
Remove the special tool.
NOTE:
- Only turn the engine in the normal direction of rotation.
Fig 35: Removing Special Tool (2 Of 2)
Courtesy of MAZDA MOTORS CORP.
Turn the engine two complete revolutions.
NOTE:
- Only turn the engine in the normal direction of rotation.
Turn the engine until the No. 1 piston is at top dead center (TDC).
Install the special tool.

Fig 36: Installing Special Tool
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- Only hand-tighten the bolt or damage to the front cover can occur.
Using the 6-mm (0.23-in) x 18-mm (0.7-in) bolt, check the position of the crankshaft pulley.
- If it is not possible to install the bolt, correct the engine timing.
  
  Fig 37: Checking Position Of Crankshaft Pulley Using Bolt
  Courtesy of MAZDA MOTORS CORP.
Using the special tool, check the position of the camshafts.
- If it is not possible to install the special tool, correct the engine timing.
  
  Fig 38: Checking Position Of Crankshaft Using Special Tool
  Courtesy of MAZDA MOTORS CORP.
Remove the special tool.

Fig 39: Removing Special Tool
Courtesy of MAZDA MOTORS CORP.
Remove the 6-mm (0.23-in) x 18-mm (0.7-in) bolt.

Fig 40: Removing Bolt
Courtesy of MAZDA MOTORS CORP.
Remove the special tool.

Fig 41: Removing Special Tool
Courtesy of MAZDA MOTORS CORP.
Install the plug bolt.

Fig 42: Installing Plug Bolt - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The crankshaft position (CKP) sensor alignment tool is supplied with the new sensor and is not available separately.
Using the special tool, install a new crankshaft position (CKP) sensor. The tool must engage a tooth of the vibration damper.

Fig 43: Installing Crankshaft Position (CKP) Sensor - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Clean the valve cover gasket surface with metal surface cleaner.
Apply silicone gasket and sealant to the locations shown.

Fig 44: Applying Silicone Gasket And Sealant
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The valve cover must be secured within four minutes of silicone gasket application. If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner.
Install the valve cover.

Fig 45: Installing Valve Cover Bolts In Sequence - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the following:
- Camshaft position (CMP) sensor.
- Cylinder head temperature (CHT) sensor.
- Spark plugs.
  
  Fig 46: Installing CMP Sensor, CHT Sensor & Spark Plugs - With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
  NOTE:
  - Clean the water pump gasket surface with metal surface cleaner.
  NOTE:
  - Lubricate the water pump O-ring seal with clean engine coolant prior to assembly.
Install the coolant pump.

Fig 47: Installing Coolant Pump Bolts - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the coolant pump pulley.

Fig 48: Installing Coolant Pump Pulley Bolts - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the fuel injection supply manifold and the ground strap.

Fig 49: Installing Fuel Injection Supply Manifold And Ground Strap - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the left motor mount.

Fig 50: Installing Left Motor Mount - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- The knock sensor must not touch the engine vent cover.
Install the engine vent cover and the knock sensor (KS).

Fig 51: Installing Engine Vent Cover And Knock Sensor (KS) - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Clean the thermostat housing gasket surface with metal surface cleaner.
Install a new gasket and the thermostat housing.

Fig 52: Installing Thermostat Housing - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the ignition coil.
NOTE:
- Apply silicone dielectric compound to the inside of the spark plug boots.
Fig 53: Installing Ignition Coil - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Connect the spark plug wires to the spark plugs.
Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.

Fig 54: Positioning Fuel Charging Wiring Harness
Courtesy of MAZDA MOTORS CORP.
Connect the ignition coil and the CHT sensor electrical connectors.

Fig 55: Connecting CHT Sensor Electrical Connectors
Courtesy of MAZDA MOTORS CORP.
Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.

Fig 56: Connecting Fuel Injector Electrical Connectors
Courtesy of MAZDA MOTORS CORP.
Install the intake manifold.

Fig 57: Installing Intake Manifold Bolts - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Secure the fuel hose clip to the intake manifold.

Fig 58: Securing Fuel Hose Clip To Intake Manifold
Courtesy of MAZDA MOTORS CORP.
Install the exhaust gas recirculation (EGR) tube.
- Install the EGR tube bracket to the intake manifold.
- Connect the EGR tube to the cylinder head.
  
  Fig 59: Installing Exhaust Gas Recirculation (EGR) Tube - With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
Connect the EGR tube to the intake manifold.

Fig 60: Connecting EGR Tube To Intake Manifold - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Attach the engine wiring harness pin-type retainers to the intake manifold.
Connect the CMP sensor electrical connector and the PCV hose.

Fig 61: Connecting CMP Sensor Electrical Connector And PCV Hose
Courtesy of MAZDA MOTORS CORP.
Install the engine wiring harness connector bracket and connect the knock sensor electrical connector.

Fig 62: Installing Engine Wiring Harness Connector Bracket
Courtesy of MAZDA MOTORS CORP.
Connect the CKP sensor and wiring pin-type retainers.

Fig 63: Connecting CKP Sensor And Wiring Pin-Type Retainers
Courtesy of MAZDA MOTORS CORP.
Connect the following electrical connectors:
- Manifold absolute pressure (MAP) sensor.
- Throttle position (TP) sensor.
- Idle air control (IAC) valve.
  
  Fig 64: Connecting Electrical Connectors
  Courtesy of MAZDA MOTORS CORP.
Install the power steering pump assembly.

Fig 65: Installing Power Steering Pump Assembly
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Clean the EGR valve gasket surface with metal surface cleaner.
Install a new gasket and the EGR valve. Connect the EGR electrical connector and coolant hose.

Fig 66: Installing EGR Valve - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Clean the rear coolant outlet pipe gasket surface with metal surface cleaner.
Install a new gasket and the rear coolant outlet pipe.
1. Tighten the bolts.
2. Connect the coolant hose.
3. Connect the engine coolant temperature sender unit electrical connector.
  
  Fig 67: Installing Rear Coolant Outlet Pipe - With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
Install the block heater, if so equipped.

Fig 68: Installing Block Heater
Courtesy of MAZDA MOTORS CORP.
Install the gasket and the exhaust manifold.

Fig 69: Installing Exhaust Manifold - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the coolant tube assembly.

Fig 70: Installing Coolant Tube Assembly
Courtesy of MAZDA MOTORS CORP.
Connect the following:
- Coolant hose to the thermostat.
- Coolant hose to the PCV fitting on the intake manifold.
Fig 71: Connecting Coolant Hose To Thermostat
Courtesy of MAZDA MOTORS CORP.
Install the right motor mount.

Fig 72: Installing Right Motor Mount - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Position the FEAD bracket and install the bolts in the sequence shown in two stages.
- Stage 1: Install finger tight.
- Stage 2: Tighten to 47 Nm (35 lb-ft).
  
  Fig 73: Identifying Tightening Sequence Of FEAD Bracket Bolts
  Courtesy of MAZDA MOTORS CORP.
Install the A/C compressor.

Fig 74: Installing A/C Compressor - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Lubricate the O-ring seal with engine coolant.
Install the front coolant outlet pipe.

Fig 75: Installing Coolant Outlet Pipe - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
NOTE:
- Lubricate the O-ring seal with clean engine oil.
Install the engine oil level indicator tube and the bolt.
- Install the oil level indicator.
  
  Fig 76: Installing Engine Oil Level Indicator Tube - With Torque Specification
  Courtesy of MAZDA MOTORS CORP.
Install the accessory drive belt.

Fig 77: Installing Accessory Drive Belt
Courtesy of MAZDA MOTORS CORP.
Using the spreader bar and the floor crane, remove the engine from the engine stand.
Install the flywheel or the flexplate and the bolts.
Install the special tool.

Fig 78: Installing Special Tool
Courtesy of MAZDA MOTORS CORP.
Tighten the bolts in the sequence shown in three stages.
- Stage 1: Tighten to 50 Nm (37 lb-ft).
- Stage 2: Tighten to 80 Nm (59 lb-ft).
- Stage 3: Tighten to 112 Nm (83 lb-ft).
Fig 79: Identifying Tightening Sequence Of Flywheel Bolts
Courtesy of MAZDA MOTORS CORP.

Vehicles with manual transmission

Lubricate the transmission input shaft pilot bearing with front axle grease.

Fig 80: Lubricating Transmission Input Shaft Pilot Bearing With Front Axle Grease
Courtesy of MAZDA MOTORS CORP.
Install a new gasket and the rear coolant outlet pipe.
1. Using a suitable press, press downward on the fingers until the adjusting ring moves freely.
2. Rotate the adjusting ring counterclockwise to compress the tension springs. Hold the adjusting ring in this position.
3. Release the pressure on the fingers. The adjusting ring will stay in the reset position.
  
  Fig 81: Installing Tension Spring
  Courtesy of MAZDA MOTORS CORP.
Using the special tool, position the clutch disc on the flywheel.

Fig 82: Positioning Clutch Disc On Flywheel
Courtesy of MAZDA MOTORS CORP.
NOTE:
- If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.
- Remove the clutch disc aligner.
Fig 83: Tightening Clutch Pressure Plate Bolts - With Torque Specification
Courtesy of MAZDA MOTORS CORP.