Engine Front Cover Removal/Installation - 2.3L: Installation

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.

NOTE:

This step is needed only if a new front cover is being installed.

Install the fan drive pulley using a nut and bolt with flat washers.

Fig 1: Identifying Fan Drive Pulley

Courtesy of MAZDA MOTORS CORP.

Clean and inspect the mounting surfaces of the engine and the front cover.
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.
NOTE:
- The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
Apply a 2.5 mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.

Fig 2: Applying Bead Of Silicone Gasket And Sealant To Front Cover
Courtesy of MAZDA MOTORS CORP.
Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:
- Tighten the 8 mm bolts to 10 N.m {1 kgf.m, 7 lbf}.
- Tighten the 10 mm bolts to 25 N.m {2.5 kgf.m, 18 lbf}.
- Tighten the 13 mm bolts to 48 N.m {4.889 kgf.m, 35 lbf}.
  CAUTION:
  - There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up one of the holes in the pulley with the bolt.
    
    Fig 3: Identifying Tightening Sequence Of Front Cover Bolts
    Courtesy of MAZDA MOTORS CORP.
Position the power steering pump and install the lower retaining bolt.

Fig 4: Installing Lower Retaining Bolt - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Connect the PSP switch electrical connector.

Fig 5: Connecting PSP Switch Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Install the water pump pulley.

Fig 6: Installing Water Pump Pulley Bolts - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the belt tensioner.

Fig 7: Installing Belt Tensioner - With Torque Specification
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. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
Install the crankshaft pulley. See CRANKSHAFT PULLEY REMOVAL/INSTALLATION - 2.3L and hand-tighten the bolt.

Fig 8: Installing Crankshaft Pulley Bolt
Courtesy of MAZDA MOTORS CORP.
NOTE:
- A new CKP sensor must be installed whenever the old sensor is removed.
Install a new CKP sensor, do not tighten the bolts at this time.

Fig 9: Installing CKP Sensor
Courtesy of MAZDA MOTORS CORP.
Adjust the CKP sensor with the Alignment Tool, and tighten the mounting bolts.

Fig 10: Adjusting CKP Sensor & Tightening Bolts - With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.

Fig 11: Connecting CKP Sensor Electrical Connector And Wiring Harness Pin-Type Retainers

Courtesy of MAZDA MOTORS CORP.

Connect the battery ground cable. See BATTERY DISCONNECT .