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Home >> Mazda >> 2005 >> B4000 SE, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 607 (Engine Mechanical [Service Information 2.3L]) >> Engine Disassembly And Assembly - 2.3L >> Disassembly >> Vehicles with manual transmission

Vehicles with manual transmission

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.
CAUTION:
  • If the clutch disc and pressure plate are to be reinstalled, bolts must be removed evenly or permanent damage to the diaphragm spring will occur, resulting in complete clutch release.
NOTE:
  • If the parts are to be reused, index-mark the clutch pressure plate to the flywheel.
  1. Remove the bolts, the clutch pressure plate and the clutch disc.
    Fig 1: Removing Clutch Pressure Plate Bolts
    G03728245Courtesy of MAZDA MOTORS CORP.

    2. All vehicles 

  2. Install the special tool and remove the flexplate.
    Fig 2: Installing Special Tool
    G03728246Courtesy of MAZDA MOTORS CORP.
  3. Mount the engine on a suitable engine stand.
  4. Remove the drive belt.
    Fig 3: Removing Drive Belt
    G03728247Courtesy of MAZDA MOTORS CORP.
  5. Remove the engine oil level indicator assembly.
    1. Remove the engine oil level indicator.
    2. Remove the bolts.
    3. Remove the engine oil level indicator tube.
    Fig 4: Removing Engine Oil Level Indicator Assembly
    G03728248Courtesy of MAZDA MOTORS CORP.
  6. Remove the front coolant outlet pipe.
    1. Remove the bolts.
    2. Remove the water outlet tube.
      Fig 5: Removing Front Coolant Outlet Pipe
      G03728249Courtesy of MAZDA MOTORS CORP.
  7. Remove the A/C compressor.
    Fig 6: Removing A/C Compressor
    G03728250Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The generator will be removed with the accessory bracket.
  8. Remove the accessory bracket.
    Fig 7: Removing Accessory Bracket
    G03728251Courtesy of MAZDA MOTORS CORP.
  9. Remove the right motor mount.
    Fig 8: Removing Right Motor Mount
    G03728252Courtesy of MAZDA MOTORS CORP.
  10. Disconnect the following:
    • the coolant hose from the thermostat.
    • the coolant hose from the PCV fitting on the intake manifold.
      Fig 9: Disconnecting Coolant Hose From PCV
      G03728253Courtesy of MAZDA MOTORS CORP.
  11. Remove the coolant tube assembly.
    Fig 10: Removing Coolant Tube Assembly
    G03728254Courtesy of MAZDA MOTORS CORP.
  12. Remove the exhaust manifold and gasket.
    Fig 11: Removing Exhaust Manifold
    G03728255Courtesy of MAZDA MOTORS CORP.
  13. Remove the block heater, if so equipped.
    Fig 12: Removing Block Heater
    G03728256Courtesy of MAZDA MOTORS CORP.
  14. Remove the rear coolant outlet pipe.
    1. Disconnect the engine coolant temperature sender electrical connector.
    2. Remove the coolant hose.
    3. Remove the rear coolant outlet pipe and the mounting gasket.
      Fig 13: Removing Rear Coolant Outlet Pipe
      G03728257Courtesy of MAZDA MOTORS CORP.
  15. Remove the EGR valve.
    1. Disconnect the electrical connector.
    2. Disconnect the coolant hose.
    3. Remove the bolts and EGR valve.
      Fig 14: Removing EGR Valve
      G03728258Courtesy of MAZDA MOTORS CORP.
  16. Remove the power steering pump.
    Fig 15: Removing Power Steering Pump
    G03728259Courtesy of MAZDA MOTORS CORP.
  17. Disconnect the following electrical connectors:
    • idle air control (IAC) valve
    • throttle position (TP) sensor
    • manifold absolute pressure (MAP) sensor
    Fig 16: Disconnecting Electrical Connectors
    G03728260Courtesy of MAZDA MOTORS CORP.
  18. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
    Fig 17: Disconnecting Crankshaft Position (CKP) Sensor And Wiring Harness Pin-Type Retainers
    G03728261Courtesy of MAZDA MOTORS CORP.
  19. Disconnect the knock sensor (KS) electrical connector and remove the engine wiring harness connector bracket. Position the engine wiring harness aside.
    Fig 18: Removing Knock Sensor (KS) Electrical Connector And Engine Wiring Harness Connector Bracket
    G03728262Courtesy of MAZDA MOTORS CORP.
  20. Disconnect the camshaft position (CMP) sensor electrical connector and disconnect the PCV hose from the intake manifold.
    Fig 19: Disconnecting Camshaft Position Sensor Electrical Connector & PCV Hose
    G03728263Courtesy of MAZDA MOTORS CORP.
  21. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
    Fig 20: Disconnecting EGR Tube From Intake Manifold
    G03728264Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the EGR tube from the intake manifold.
  23. Remove the EGR tube.
    • Remove the EGR tube bracket from the intake manifold.
    • Disconnect the EGR tube from the cylinder head.
    • Remove the EGR tube.
    Fig 21: Removing EGR Tube
    G03728265Courtesy of MAZDA MOTORS CORP.
  24. Detach the fuel supply hose clip from the front of the intake manifold.
    Fig 22: Detaching Fuel Supply Hose Clip From Front Of Intake Manifold
    G03728266Courtesy of MAZDA MOTORS CORP.
  25. Remove the intake manifold assembly.
    Fig 23: Removing Intake Manifold Assembly
    G03728267Courtesy of MAZDA MOTORS CORP.
  26. Disconnect the fuel injector electrical connectors and the wiring harness pin-type retainers.
    Fig 24: Disconnecting Fuel Injector Electrical Connectors
    G03728268Courtesy of MAZDA MOTORS CORP.
  27. Disconnect the ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.
    Fig 25: Disconnecting Ignition Coil And Cylinder Head Temperature Sensor Electrical Connector
    G03728269Courtesy of MAZDA MOTORS CORP.
  28. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
    Fig 26: Removing Engine Wiring Harness Anchors
    G03728270Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
    CAUTION:
    • It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wires.
  29. With a twisting motion, use the special tool to pull the spark plug wires off the spark plugs.
    Fig 27: Pulling Spark Plug Wires
    G03728271Courtesy of MAZDA MOTORS CORP.
  30. Remove the ignition coil.
    Fig 28: Removing Ignition Coil
    G03728272Courtesy of MAZDA MOTORS CORP.
  31. Remove the thermostat housing.
    Fig 29: Removing Thermostat Housing
    G03728273Courtesy of MAZDA MOTORS CORP.
  32. Remove the knock sensor (KS) and the engine vent cover.
    Fig 30: Removing Knock Sensor (KS)
    G03728274Courtesy of MAZDA MOTORS CORP.
  33. Remove the left motor mount.
    Fig 31: Removing Left Motor Mount
    G03728275Courtesy of MAZDA MOTORS CORP.
  34. Remove the fuel injector supply manifold with the injectors and the ground strap.
    Fig 32: Removing Fuel Injector Supply Manifold
    G03728276Courtesy of MAZDA MOTORS CORP.
  35. Remove the water pump pulley.
    Fig 33: Removing Water Pump Pulley
    G03728277Courtesy of MAZDA MOTORS CORP.
  36. Remove the water pump.
    Fig 34: Removing Water Pump
    G03728278Courtesy of MAZDA MOTORS CORP.
  37. Remove the following:
    1. camshaft position (CMP) sensor
    2. cylinder head temperature (CHT) sensor
    3. spark plugs
      Fig 35: Removing CMP Sensor, CHT Sensor & Spark Plugs
      G03728279Courtesy of MAZDA MOTORS CORP.
  38. Remove the valve cover.
    NOTE:
    • The crankshaft position (CKP) sensor cannot be reused. A new CKP sensor must be installed.
    Fig 36: Removing Valve Cover
    G03728280Courtesy of MAZDA MOTORS CORP.
  39. Remove the crankshaft position (CKP) sensor.
    Fig 37: Removing Crankshaft Position (CKP) Sensor
    G03728281Courtesy 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. For that reason, if the pulley is loosened, the crankshaft sprocket is also unfastened. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
    CAUTION:
    • 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.
  40. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No.1 piston at TDC.
    Fig 38: Identifying Crankshaft Pulley Bolt
    G03728282Courtesy 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.
    NOTE:
    • The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
  41. Install the special tool in the slots on the rear of both camshafts.
    Fig 39: Installing Special Tool In Slots On Rear Of Both Camshafts
    G03728283Courtesy of MAZDA MOTORS CORP.
  42. Install the special tools.
    Fig 40: Installing Special Tool
    G03728284Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Failure to hold the crankshaft pulley in place while loosening the bolts can cause damage to the engine.
  43. Remove the crankshaft pulley.
    1. Remove the crankshaft pulley bolt.
    2. Remove the special tools.
    3. Remove the crankshaft pulley.
      Fig 41: Removing Crankshaft Pulley
      G03728285Courtesy of MAZDA MOTORS CORP.
      CAUTION:
      • There is one front cover bolt behind the cooling fan drive pulley. To remove this bolt, align one of the cooling fan drive pulley access holes with the bolt head.
  44. Remove the front cover.
    Fig 42: Removing Front Cover
    G03728286Courtesy of MAZDA MOTORS CORP.
  45. Remove the timing chain tensioner.
    1. Compress the timing chain tensioner plunger and insert a paper clip into the location shown.
    2. Remove the bolts.
    Fig 43: Removing Timing Chain Tensioner
    G03728287Courtesy of MAZDA MOTORS CORP.
  46. Remove the timing chain guides.
    Fig 44: Removing Timing Chain Guides
    G03728288Courtesy of MAZDA MOTORS CORP.
  47. Remove the timing chain assembly.
    Fig 45: Removing Timing Chain Assembly
    G03728289Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Use a wrench on the flats between cylinders No. 1 and No. 2 to hold the camshaft in place.
  48. Remove the camshaft drive sprockets.
    Fig 46: Removing Camshaft Drive Sprockets
    G03728290Courtesy of MAZDA MOTORS CORP.
  49. Remove the oil pump chain tensioner and guide.
    1. Release the tension on the tensioner spring.
    2. Remove the tensioner and the shoulder bolt.
    3. Remove the guide.
      Fig 47: Removing Oil Pump Chain Tensioner And Guide
      G03728291Courtesy of MAZDA MOTORS CORP.
      NOTE:
      • The oil pump chain sprocket must be held in place.
  50. Remove the oil pump chain and sprockets.
    1. Remove the bolt.
    2. Remove the chain, sprockets and diamond washers.
    Fig 48: Removing Oil Pump Chain And Sprockets
    G03728292Courtesy of MAZDA MOTORS CORP.
  51. Remove the special tool.
    Fig 49: Removing Special Tool
    G03728293Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
    NOTE:
    • Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference.
  52. Remove the camshaft bearing caps.
    • Loosen the camshaft bearing cap bolts in sequence, one turn at a time.
    • Repeat the first step until all tension is released from the camshaft bearing caps.
    • Remove the camshaft bearing caps.
    Fig 50: Loosening Camshaft Bearing Cap Bolts In Sequence
    G03728294Courtesy of MAZDA MOTORS CORP.
  53. Remove the camshafts.
  54. Remove the bolts and the cylinder head.
    Fig 51: Removing Cylinder Head Bolts
    G03728295Courtesy of MAZDA MOTORS CORP.
  55. Remove the cylinder head gasket.
  56. Remove the cylinder head alignment dowels.
    Fig 52: Removing Cylinder Head Alignment Dowels
    G03728296Courtesy of MAZDA MOTORS CORP.
  57. Remove the bolts and the oil pan.
    Fig 53: Removing Oil Pan Bolts
    G03728297Courtesy of MAZDA MOTORS CORP.
  58. Remove the rear main oil seal.
    Fig 54: Removing Rear Main Oil Seal Bolts
    G03728298Courtesy of MAZDA MOTORS CORP.
  59. Remove the oil pump pickup tube and gasket.
    Fig 55: Removing Oil Pump Pickup Tube And Gasket
    G03728299Courtesy of MAZDA MOTORS CORP.
  60. Remove the oil pump assembly and gasket.
    Fig 56: Removing Oil Pump Assembly And Gasket
    G03728300Courtesy of MAZDA MOTORS CORP.
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