Engine Disassembly And Assembly - 2.3L: Assembly

All vehicles 

1. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at top dead center (TDC).
   Fig 1: Locating Plug Bolt

   Courtesy of MAZDA MOTORS CORP.
2. Remove the plug bolt.
   Fig 2: Identifying Crankshaft TDC Timing Peg SST

   Courtesy of MAZDA MOTORS CORP.
   NOTE:

   • Only turn the engine in the normal direction of rotation.
   NOTE:

   • Installing the crankshaft TDC timing peg SST  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.
3. Install the crankshaft TDC timing peg SST. 
   Fig 3: Identifying Oil Pump Assembly Bolts Tightening Sequence

   Courtesy of MAZDA MOTORS CORP.
   NOTE:

   • Clean the sealing surface with metal surface cleaner.
4. 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 4: Oil Pump Pickup Tube Bolts Tightening Sequence With Torque Specifications

   Courtesy of MAZDA MOTORS CORP.
   NOTE:

   • Clean the sealing surface with a metal surface cleaner.
5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten the bolts in the sequence shown.
   Fig 5: Identifying Main Oil Seal Installer

   Courtesy of MAZDA MOTORS CORP.
6. Using the crankshaft rear main oil seal installer SST  , install the rear main oil seal.
   Fig 6: Tightening Sequence Of Rear Main Oil Seal Bolts With Torque Specifications

   Courtesy of MAZDA MOTORS CORP.
7. Tighten the rear main oil seal bolts in the sequence shown.
   Fig 7: Tightening Sequence Of Oil Pan 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.
   • 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.
8. 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 8: Locating Cylinder Head Alignment Dowels

   Courtesy of MAZDA MOTORS CORP.
9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
   Fig 9: Identifying Silicone Gasket And Sealant Applying Point

   Courtesy of MAZDA MOTORS CORP.
   NOTE:

   • Clean the gasket surface with metal surface cleaner.
10. Apply silicone gasket and sealant to the locations shown.
11. Install a new cylinder head gasket.
12. Clean the cylinder head gasket surface with metal surface cleaner.
    Fig 10: Identifying Tightening Sequence Of Cylinder Head Bolts

    Courtesy of MAZDA MOTORS CORP.
    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.
13. 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 11: Identifying Camshaft Bearing Cap Bolts Tightening Sequence

    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.
14. 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 12: Locating Camshaft Sprockets

    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.
15. Install the washers and the oil pump chain and sprockets.
    • The crankshaft sprocket flange must be facing away from the engine block.
    Fig 13: Oil Pump Sprocket Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • The oil pump chain sprocket must be held in place.
16. Tighten the oil pump sprocket bolt.
    Fig 14: Oil Pump Chain Guide And Shoulder Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
17. Install the oil pump chain guide and the shoulder bolts.
    Fig 15: Locating Oil Pump Chain Tensioner With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    Fig 16: Locating Camshaft Drive Sprockets And Bolts

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Sprockets must turn freely on the camshafts.
19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.
    Fig 17: Locating Ratchet

    Courtesy of MAZDA MOTORS CORP.
    CAUTION:

    • Do not compress the ratchet assembly. This will damage the ratchet assembly.
20. Using the edge of a vise, compress the timing chain tensioner plunger.
    Fig 18: Locating Small Pick

    Courtesy of MAZDA MOTORS CORP.
21. Using a small pick, push back and hold the ratchet mechanism.
    Fig 19: Pushing Ratchet Arm Back Into Tensioner Housing

    Courtesy of MAZDA MOTORS CORP.
22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 20: Installing Paper Clip Into Hole In Tensioner Housing

    Courtesy of MAZDA MOTORS CORP.
23. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.
    Fig 21: Locating Timing Chain Assembly

    Courtesy of MAZDA MOTORS CORP.
24. Install the timing chain
    Fig 22: Locating Timing Chain Guides With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
25. Install the timing chain guides.
    Fig 23: Locating Timing Chain Tensioner With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
    Fig 24: Identifying Camshaft Alignment Plate (303-465)

    Courtesy of MAZDA MOTORS CORP.
    CAUTION:

    • The camshaft alignment plate SST is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
27. Install the camshaft alignment plate SST in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
    Fig 25: Camshaft Sprocket Bolts With Torque Specifications

    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.
28. Tighten the camshaft sprocket bolts.
29. Clean the front cover gasket surface with metal surface cleaner.
    Fig 26: Locating Areas For Applying Silicone Gasket And Sealant To Cylinder Head And Oil Pan Joint

    Courtesy of MAZDA MOTORS CORP.
30. Apply a 2.5 mm (0.1 in) bead of silicone gasket and sealant to the front cover.
    Fig 27: Locating Silicone Gasket And Sealant Applying Points

    Courtesy of MAZDA MOTORS CORP.
31. Apply silicone gasket and sealant to the locations shown.
    Fig 28: Identifying Tightening Sequence Of Front Cover Bolts

    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.
32. 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 29: Locating Crankshaft Pulley Bolt

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Do not reuse the crankshaft pulley bolt.
    NOTE:

    • Apply clean engine oil on the seal area before installing.
33. Install the crankshaft pulley and hand-tighten the bolt.
    Fig 30: Locating M6 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.
34. 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 31: Identifying Holding Fixture And Crankshaft Pulley/Holding Tool

    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.
35. Using the holding fixture SST  and the crankshaft pulley / holding tool SST  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 32: Identifying Holding Fixture And Crankshaft Pulley/Holding Tool

    Courtesy of MAZDA MOTORS CORP.
36. Remove the holding fixture SST  and the crankshaft pulley / holding tool SST  .
    Fig 33: Locating M6 Bolt

    Courtesy of MAZDA MOTORS CORP.
37. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 34: Identifying Crankshaft TDC Timing Peg SST

    Courtesy of MAZDA MOTORS CORP.
38. Remove the crankshaft timing peg SST.
    Fig 35: Identifying Camshaft Alignment Plate (303-465)

    Courtesy of MAZDA MOTORS CORP.
39. Remove the camshaft alignment plate SST.
    NOTE:

    • Only turn the engine in the normal direction of rotation.
40. Turn the engine two complete revolutions.
    NOTE:

    • Only turn the engine in the normal direction of rotation.
41. Turn the engine until the No. 1 piston is at top dead center (TDC).
    Fig 36: Identifying Crankshaft TDC Timing Peg SST

    Courtesy of MAZDA MOTORS CORP.
42. Install the crankshaft timing peg SST.
    Fig 37: Locating M6 Bolt

    Courtesy of MAZDA MOTORS CORP.
    CAUTION:

    • Only hand-tighten the bolt or damage to the front cover can occur.
43. 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 38: Identifying Camshaft Alignment Plate (303-465)

    Courtesy of MAZDA MOTORS CORP.
44. Using the camshaft alignment plate SST  , check the position of the camshafts.
    • If it is not possible to install the special tool, correct the engine timing.
    Fig 39: Identifying Camshaft Alignment Plate (303-465)

    Courtesy of MAZDA MOTORS CORP.
45. Remove the camshaft alignment plate SST.
    Fig 40: Locating M6 Bolt

    Courtesy of MAZDA MOTORS CORP.
46. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 41: Identifying Crankshaft TDC Timing Peg SST

    Courtesy of MAZDA MOTORS CORP.
47. Remove the crankshaft timing peg SST  .
    Fig 42: Plug Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
48. Install the timing peg plug.
    Fig 43: Locating CKP Sensor Alignment Tool With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • The crankshaft position (CKP) sensor alignment tool is supplied with the new sensor and is not available separately.
49. Using the CKP sensor alignment tool, install a new CKP sensor. The CKP sensor alignment tool must engage a tooth of the vibration damper.
50. Clean the valve cover gasket surface with metal surface cleaner.
    Fig 44: Locating Silicone Gasket And Sealant Applying Points

    Courtesy of MAZDA MOTORS CORP.
51. Apply silicone gasket and sealant to the locations shown.
    Fig 45: Tightening Sequence Of Valve Cover Bolts With Torque Specifications

    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.
52. Install the valve cover.
    Fig 46: Camshaft Position (CMP) Sensor, Cylinder Head Temperature (CHT) Sensor And Spark Plugs With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
53. Install the camshaft position (CMP) sensor, cylinder head temperature (CHT) sensor and spark plugs.
    Fig 47: Water Pump Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Clean the water pump gasket surface with metal surface cleaner.
    NOTE:

    • Lubricate the coolant pump O-ring seal with clean engine coolant prior to assembly.
54. Install the coolant pump.
    Fig 48: Coolant Pump Pulley Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
55. Install the coolant pump pulley.
    Fig 49: Fuel Injection Supply Manifold And Ground Strap With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
56. Install the fuel injection supply manifold and the ground strap.
    Fig 50: Left Motor Mount Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
57. Install the left motor mount.
    Fig 51: Engine Vent Cover And Knock Sensor (KS) With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • The knock sensor must not touch the engine vent cover.
58. Install the engine vent cover and the knock sensor (KS).
    Fig 52: Gasket And Thermostat Housing Bolt With Torque Specifications

    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 53: Ignition Coil Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
59. Install the ignition coil.
    NOTE:

    • Apply silicone dielectric compound to the inside of the spark plug boots.
60. Connect the spark plug wires to the spark plugs.
    Fig 54: Locating Wiring Harness

    Courtesy of MAZDA MOTORS CORP.
61. Position the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
    Fig 55: Locating Ignition Coil And Cylinder Head Temperature (CHT) Sensor Electrical Connectors

    Courtesy of MAZDA MOTORS CORP.
62. Connect the ignition coil and the CHT sensor electrical connectors.
    Fig 56: Locating Fuel Injector Electrical Connectors

    Courtesy of MAZDA MOTORS CORP.
63. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.
    Fig 57: Intake Manifold Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
64. Install the intake manifold.
    Fig 58: Locating Fuel Supply Hose Clip

    Courtesy of MAZDA MOTORS CORP.
65. Secure the fuel hose clip to the intake manifold.
    Fig 59: Locating Exhaust Gas Recirculation (EGR) Tube And Bracket

    Courtesy of MAZDA MOTORS CORP.
66. Install the exhaust gas recirculation (EGR) tube.
    • Install the EGR tube bracket to the intake manifold.

      Tightening Torque: 

      10 Nm {89 ft-lbi} 

    • Connect the EGR tube to the cylinder head.

    Tightening Torque: 

    55 Nm {41 ft-lbf} 

    Fig 60: EGR Tube Bolt With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
67. Connect the EGR tube to the intake manifold.
68. Attach the engine wiring harness pin-type retainers to the intake manifold.
    Fig 61: Locating Camshaft Position (CMP) Sensor Electrical Connector And PCV Hose

    Courtesy of MAZDA MOTORS CORP.
69. Connect the CMP sensor electrical connector and the PCV hose.
    Fig 62: Locating Engine Wiring Harness Connector Bracket And Knock Sensor Electrical Connector

    Courtesy of MAZDA MOTORS CORP.
70. Install the engine wiring harness connector bracket and connect the knock sensor electrical connector.

    Tightening Torque: 

    10 Nm {89 ft-lbi} 

    Fig 63: Locating Crankshaft Position (CKP) Sensor And Wiring Pin-Type Retainers

    Courtesy of MAZDA MOTORS CORP.
71. Connect the CKP sensor and wiring pin-type retainers.
    Fig 64: Locating Electrical Connectors (IAC, TP And MAP)

    Courtesy of MAZDA MOTORS CORP.
72. Connect the manifold absolute pressure (MAP) sensor, throttle position (TP) sensor and idle air control (IAC) valve electrical connectors.
    Fig 65: Locating Power Steering Pump Assembly

    Courtesy of MAZDA MOTORS CORP.
73. Install the power steering pump assembly.
    Fig 66: Locating EGR Electrical Connector And Coolant Hose With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Clean the EGR valve gasket surface with metal surface cleaner.
74. Install the EGR valve.

    Tightening Torque: 

    20 Nm {15 ft-lbf} 

    Fig 67: Identifying EGR Electrical Connector And Coolant Hose And Bolts

    Courtesy of MAZDA MOTORS CORP.
    1. Using a new gasket, position the EGR valve and install the 2 bolts.
    2. Connect the coolant hose.
    3. Connect the electrical connector.
    NOTE:

    • Clean the rear coolant outlet pipe gasket surface with metal surface cleaner.
75. Install a new gasket and the rear coolant outlet pipe.
    Fig 68: Identifying Coolant Hose And Bolts

    Courtesy of MAZDA MOTORS CORP.
    1. Tighten the bolts.

       Tightening Torque: 

       10 Nm {89 ft-lbi} 

    2. Connect the coolant hose.
    3. Connect the engine coolant temperature sender unit electrical connector.
    Fig 69: Locating Block Heater

    Courtesy of MAZDA MOTORS CORP.
76. Install the block heater, if equipped.
    Fig 70: Locating Exhaust Manifold Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
77. Install the gasket and the exhaust manifold.
    Fig 71: Locating Coolant Tube Assembly With Bolts

    Courtesy of MAZDA MOTORS CORP.
78. Install the coolant tube assembly.
    Fig 72: Locating Coolant Hoses

    Courtesy of MAZDA MOTORS CORP.
79. Connect the coolant hose to the thermostat and coolant hose to the PCV fitting on the intake manifold.
    Fig 73: Right Motor Mount Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
80. Install the right motor mount.
    Fig 74: Identifying Installing Sequence Of FEAD Bracket Bolts

    Courtesy of MAZDA MOTORS CORP.
81. 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 75: A/C Compressor Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
82. Install the A/C compressor.
    Fig 76: Installing Front Coolant Outlet Pipe Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Lubricate the O-ring seal with engine coolant.
83. Install the front coolant outlet pipe.
    Fig 77: Engine Oil Level Indicator Tube And Bolts With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • Lubricate the O-ring seal with clean engine oil.
84. Install the engine oil level indicator tube and the bolts.
    • Install the oil level indicator.
    Fig 78: Locating Drive Belt

    Courtesy of MAZDA MOTORS CORP.
85. Install the accessory drive belt.
86. Using the spreader bar and the floor crane, remove the engine from the engine stand.
87. Install the flywheel or the flexplate and the bolts.
    Fig 79: Identifying Flywheel Locking Tool SST

    Courtesy of MAZDA MOTORS CORP.
88. Install the flywheel locking tool SST.
    Fig 80: Identifying Flywheel Bolts Tightening Sequence

    Courtesy of MAZDA MOTORS CORP.
89. 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).

    Vehicles with manual transmission 

    Fig 81: Locating Transmission Input Shaft Pilot Bearing

    Courtesy of MAZDA MOTORS CORP.
90. Lubricate the transmission input shaft pilot bearing with front axle grease.
    Fig 82: Adjusting Clutch Pressure Plate

    Courtesy of MAZDA MOTORS CORP.
91. Adjust the clutch pressure plate.
    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 83: Identifying Clutch Disc Aligner

    Courtesy of MAZDA MOTORS CORP.
92. Using the clutch disc aligner SST  , position the clutch disc on the flywheel.
    Fig 84: Bolts Of Clutch Pressure Plate With Torque Specifications

    Courtesy of MAZDA MOTORS CORP.
    NOTE:

    • If reusing the clutch pressure plate and flywheel, align the marks made during removal.
93. Position the clutch pressure plate and install the bolts. Tighten the bolts in a star pattern sequence.

• Remove the clutch disc aligner SST.