Engine Front Cover Removal/Installation - 2.3L: Removal

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.

Disconnect the negative battery cable.
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.
Remove the crankshaft pulley. See CRANKSHAFT PULLEY REMOVAL/INSTALLATION - 2.3L .
Disconnect the crankshaft position (CKP) sensor electrical connector and the wiring harness pin-type retainers.

Fig 1: Removing Crankshaft Position Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
NOTE:
- A new CKP sensor must be installed whenever the old sensor is removed.
Remove and discard the CKP sensor.

Fig 2: Disconnecting Crankshaft Position Sensor
Courtesy of MAZDA MOTORS CORP.
Remove the belt tensioner.

Fig 3: Removing Belt Tensioner
Courtesy of MAZDA MOTORS CORP.
Remove the water pump pulley.

Fig 4: Removing Water Pump Pulley
Courtesy of MAZDA MOTORS CORP.
Disconnect the power steering pressure (PSP) switch electrical connector.

Fig 5: Removing Power Steering Pressure Switch Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Remove the bolt and position the power steering pump aside.

Fig 6: Removing Power Steering Pump Bolt
Courtesy of MAZDA MOTORS CORP.
NOTE:
- This step is needed only if a new front cover is being installed.
Using a three-jaw puller, remove the fan drive pulley.

Fig 7: Removing Fan Drive Pulley
Courtesy of MAZDA MOTORS CORP.
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.
Remove the bolts and the engine front cover.

Fig 8: Removing Engine Front Cover Bolts
Courtesy of MAZDA MOTORS CORP.