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Home >> Mazda >> 2006 >> 6 s, 4D Wagon, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 12 (Engine Mechanical [Service Information L3 With TC)) >> Valve Clearance Inspection/Adjustment >> Valve Clearance Adjustment

Valve Clearance Adjustment

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  1. Disconnect the negative battery cable.
  2. Remove the front tire (RH).
  3. Remove the under cover.
  4. Remove the splash shield (RH).
  5. Remove the charge air cooler. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION ).
  6. Remove the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION ).
  7. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION ).
  8. Disconnect the OCV connector.
  9. Disconnect the CMP sensor connector.
  10. Disconnect the P/S oil pump connector.
  11. Remove the ventilation hose.
  12. Remove the cylinder head cover. (See CYLINDER HEAD COVER REMOVAL NOTE ).
  13. Remove the drive belt. (See DRIVE BELT REPLACEMENT ).
  14. Disconnect the front drive shaft (RH) from the joint shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L3, L3 WITH TC] ).
  15. Remove the engine front cover lower blind plug.
  16. Remove the engine front cover upper blind plug.
    Fig 1: Removing Engine Front Cover Upper Blind Plug
    G04324387Courtesy of MAZDA MOTORS CORP.
  17. Remove the cylinder block lower blind plug, and install the SST  .
  18. Rotate the crankshaft clockwise so that the No. 1 cylinder is at TDC of the compression stroke. (The position crank weight contacts the SST  ).
    Fig 2: Installing SST
    G04324388Courtesy of MAZDA MOTORS CORP.
  19. Release the tension on the timing chain.
    1. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
      Fig 3: Unlocking Chain Tensioner Ratchet
      G04324389Courtesy of MAZDA MOTORS CORP.
    2. Rotate the exhaust camshaft clockwise using a suitable wrench on the east hexagon and loosen the tension on the timing chain.
    3. Using a suitable bolt (M6 X 1.0 length 25mm-35mm {0.99-1.37 in})  at the engine front cover upper blind plug, secure the tensioner arm at the position where the tension is released.
      Fig 4: Securing Tensioner Arm Using Bolt
      G04324390Courtesy of MAZDA MOTORS CORP.
  20. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket installation bolt.
    Fig 5: Holding Camshaft Using Suitable Wrench On Cast Hexagon
    G04313478Courtesy of MAZDA MOTORS CORP.
  21. Remove the installation bolt and remove the exhaust camshaft sprocket.
    Fig 6: Removing/Installing Exhaust Camshaft Sprocket
    G04313483Courtesy of MAZDA MOTORS CORP.
  22. Loosen the camshaft cap bolts in two or three passes in the order shown in the figure and remove the camshaft cap.
    NOTE:
    • The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.
    Fig 7: Identifying Loosening Sequence Of Camshaft Cap Bolts
    G04324393Courtesy of MAZDA MOTORS CORP.
  23. Remove the camshafts for the intake and exhaust sides.
  24. Remove the tappet.
  25. Install an appropriate tappet based on the results of the valve clearance inspection.

    Selected tappet = Removed tappet thickness + Measured valve clearance - Standard valve clearance

    Standard valve clearance [Engine cold] 

    IN: 0.22-0.28 mm {0.0087-0.0110 in} 

    EX: 0.27-0.33 mm {0.0107-0.0129 in} 

  26. Install the camshaft with No. 1 cylinder cam aligned at TDC of the compression stroke.
  27. Carefully apply adhesive agent to the area indicated in the figure so that it does not leak into the sliding part.

    Thickness 1.0 mm {0.039 in} 

    Fig 8: Applying Adhesive Agent To Intake Rear Camshaft Cap
    G04324394Courtesy of MAZDA MOTORS CORP.
  28. Install the camshaft caps and temporarily tighten the camshaft cap bolts evenly in two or three passes, and then tighten the camshaft cap bolts in two passes, using the following two steps and in the order shown in the figure.

    Tightening procedure 

    1. 5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.6 in.lbf} 
    2. 14.0-17.0 N.m {1.5-1.7 kgf-m, 10.4-12.5 ft.lbf 
      Fig 9: Identifying Installing Sequence Of Camshaft Caps
      G04324395Courtesy of MAZDA MOTORS CORP.
  29. Install a new washer.
    Fig 10: Installing Washer
    G04324396Courtesy of MAZDA MOTORS CORP.
  30. Install the exhaust camshaft sprocket.
    CAUTION:
    • Do not tighten the camshaft sprocket installation bolt at this stage. Verify the valve timing before performing the bolt tightening.
    Fig 11: Removing/Installing Exhaust Camshaft Sprocket
    G04313483Courtesy of MAZDA MOTORS CORP.
  31. Install the SST  on the camshaft as shown in the figure.
  32. Remove the installation bolt for the engine front cover upper blind plug (M6 X 1.0 length 25-35mm {0.99-1.37 in})  , and apply tension to the timing chain.
  33. Rotate the crankshaft clockwise and verify that the No. 1 cylinder is at TDC of the compression stroke. (The position crank weight contacts the SST  ).
    Fig 12: Installing SST On Camshaft
    G04324398Courtesy of MAZDA MOTORS CORP.
  34. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket installation bolt.

    Tightening torque 69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf} 

    Fig 13: Holding Camshaft Using Suitable Wrench On Cast Hexagon
    G04313478Courtesy of MAZDA MOTORS CORP.
  35. Remove the SST  from the camshaft.
  36. Remove the SST  installed in the cylinder block lower blind plug hole.
  37. Rotate the crankshaft clockwise two turns and inspect the valve timing.
    • If it is not aligned, repeat the procedure.
  38. Apply the silicone sealant and install the engine front cover upper blind plug.

    Tightening torque 8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf} 

    Fig 14: Installing Engine Front Cover Upper Blind Plug
    G04324400Courtesy of MAZDA MOTORS CORP.
  39. Install the cylinder block lower blind plug.

    Tightening torque 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf} 

    Fig 15: Installing Cylinder Block Lower Blind Plug
    G04324401Courtesy of MAZDA MOTORS CORP.
  40. Install a new engine front cover lower blind plug.

    Tightening torque 10.0-14.0 N.m {102.0-142.7 kgf.cm, 73.8-103.2 in.lbf} 

    Fig 16: Identifying Engine Front Cover Lower Blind Plug
    G04313474Courtesy of MAZDA MOTORS CORP.
  41. Connect the front drive shaft (RH) with the joint shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L3, L3 WITH TC] ).
  42. Install the drive belt. (See DRIVE BELT REPLACEMENT ).
  43. Install the cylinder head cover. (See CYLINDER HEAD COVER INSTALLATION NOTE ).
  44. Install the ventilation hose.
  45. Connect the P/S oil pump connector.
  46. Connect the CMP sensor connector.
  47. Connect the OCV connector.
  48. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION ).
  49. Install the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION ).
  50. Install the charge air cooler. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION ).
  51. Install the splash shield (RH).
  52. Install the under cover.
  53. Install the front tire (RH).
  54. Connect the negative battery cable.
  55. Bleed the air from the cooling system. (See ENGINE COOLANT REPLACEMENT ).
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