LEMON Manuals: Even more car manuals for everyone
Home >> Mazda >> 2007 >> B4000 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 555 (Engine Mechanical 2.3L Service Information) >> Engine Disassembly And Assembly - 2.3L >> Disassembly

Engine Disassembly And Assembly - 2.3L: Disassembly

WARNING: This page is about a different car, the 2007 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces can enter the oil passages, coolant passages or the oil pan, and cause engine failure.
CAUTION:
  • The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using 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.
CAUTION:
  • Due to the precision fit and timing of the balancer shaft assembly, it cannot be removed from the engine block.

Vehicles with manual transmission 

Fig 1: Locating Bolts Of Clutch Pressure Plate And Clutch Disc
G04929270Courtesy of MAZDA MOTORS CORP.
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.

    All vehicles 

    Fig 2: Identifying Flywheel Locking Tool
    G04929216Courtesy of MAZDA MOTORS CORP.
  2. Install the flywheel locking tool SST  and remove the flexplate.
  3. Mount the engine on a suitable engine stand.
    Fig 3: Locating Drive Belt
    G04929272Courtesy of MAZDA MOTORS CORP.
  4. Remove the drive belt.
    Fig 4: Identifying Engine Oil Level Indicator, Bolts And Tube
    G04929273Courtesy 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 5: Identifying Water Outlet Tube And Bolts
    G04929274Courtesy of MAZDA MOTORS CORP.
  6. Remove the front coolant outlet pipe.
    1. Remove the bolts.
    2. Remove the water outlet tube.
    Fig 6: Locating Bolts Of A/C Compressor
    G04929275Courtesy of MAZDA MOTORS CORP.
  7. Remove the bolts and the A/C compressor.
    Fig 7: Locating Accessory Bracket
    G04929276Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • The generator will be removed with the accessory bracket.
  8. Remove the accessory bracket.
    Fig 8: Locating Bolts Of RH Motor Mount
    G04929277Courtesy of MAZDA MOTORS CORP.
  9. Remove the bolts and the RH motor mount.
    Fig 9: Locating Coolant Hoses
    G04929278Courtesy of MAZDA MOTORS CORP.
  10. Disconnect the following the coolant hose from the thermostat and the coolant hose from the positive crankcase ventilation (PCV) fitting on the intake manifold.
    Fig 10: Locating Coolant Tube Assembly
    G04929279Courtesy of MAZDA MOTORS CORP.
  11. Remove the coolant tube assembly.
    Fig 11: Locating Exhaust Manifold And Gasket
    G04929280Courtesy of MAZDA MOTORS CORP.
  12. Remove the exhaust manifold and gasket.
    Fig 12: Locating Block Heater
    G04929281Courtesy of MAZDA MOTORS CORP.
  13. Remove the block heater, if equipped.
    Fig 13: Identifying Coolant Hose And Bolts
    G04929282Courtesy of MAZDA MOTORS CORP.
  14. Remove the rear coolant outlet pipe.
    1. Remove the coolant hose.
    2. Remove the rear coolant outlet pipe and the mounting gasket.
    Fig 14: Identifying Electrical Connector, Coolant Hose And EGR Valve
    G04929283Courtesy 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 15: Locating Power Steering Pump Bolts
    G04929284Courtesy of MAZDA MOTORS CORP.
  16. Remove the power steering pump.
    Fig 16: Locating Electrical Connectors (IAC, TP And MAP)
    G04929285Courtesy 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 17: Locating Crankshaft Position (CKP) Sensor And Pin-Type Retainers
    G04929286Courtesy of MAZDA MOTORS CORP.
  18. Disconnect the crankshaft position (CKP) sensor and the wiring harness pin-type retainers.
    Fig 18: Locating Knock Sensor (KS) Electrical Connector And Harness Bracket Bolts
    G04929287Courtesy of MAZDA MOTORS CORP.
  19. Disconnect the knock sensor (KS) electrical connector, remove the three bolts and position the engine wiring harness and bracket aside.
    Fig 19: Locating Camshaft Position (CMP) Sensor Electrical Connector And PCV Hose
    G04929288Courtesy of MAZDA MOTORS CORP.
  20. Disconnect the camshaft position (CMP) sensor electrical connector and disconnect the PCV hose from the intake manifold.
  21. Disconnect the engine wiring harness pin-type retainers from the intake manifold.
    Fig 20: Locating EGR Bolts
    G04929289Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the EGR tube from the intake manifold.
    Fig 21: Locating EGR Tube And Bracket
    G04929290Courtesy of MAZDA MOTORS CORP.
  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 22: Locating Fuel Supply Hose Clip
    G04929291Courtesy of MAZDA MOTORS CORP.
  24. Detach the fuel supply hose clip from the front of the intake manifold.
    Fig 23: Locating Intake Manifold Assembly Bolts
    G04929292Courtesy of MAZDA MOTORS CORP.
  25. Remove the intake manifold assembly.
    Fig 24: Locating Four Fuel Injector Electrical Connectors And Two Wiring Harness Pin-Type Retainers
    G04929293Courtesy of MAZDA MOTORS CORP.
  26. Disconnect the four fuel injector electrical connectors and the two wiring harness pin-type retainers.
    Fig 25: Locating Ignition Coil And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G04929294Courtesy of MAZDA MOTORS CORP.
  27. Disconnect the ignition coil and the cylinder head temperature (CHT) sensor electrical connectors.
    Fig 26: Locating Wiring Harness
    G04929295Courtesy of MAZDA MOTORS CORP.
  28. Detach the engine wiring harness anchors from the valve cover studs. Remove the engine wiring harness.
    Fig 27: Pulling Spark Plug Wire Using Spark Plug Wire Remover
    G04929296Courtesy 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 spark plug wire remover SST  to pull the spark plug wires off the spark plugs.
    Fig 28: Locating Ignition Coil Bolts
    G04929297Courtesy of MAZDA MOTORS CORP.
  30. Remove the ignition coil
    Fig 29: Locating Thermostat Housing Bolt
    G04929298Courtesy of MAZDA MOTORS CORP.
  31. Remove the thermostat housing.
    Fig 30: Removing Knock Sensor (KS)
    G04929299Courtesy of MAZDA MOTORS CORP.
  32. Remove the bolt, the knock sensor (KS) and the engine vent cover.
    Fig 31: Locating Left Motor Mount Bolt
    G04929300Courtesy of MAZDA MOTORS CORP.
  33. Remove the left motor mount.
    Fig 32: Locating Fuel Injector Supply Manifold Bolt
    G04929301Courtesy of MAZDA MOTORS CORP.
  34. Remove the fuel injector supply manifold with the injectors and the ground strap.
    Fig 33: Locating Water Pump Pulley Bolt
    G04929302Courtesy of MAZDA MOTORS CORP.
  35. Remove the water pump pulley.
    Fig 34: Locating Water Pump Bolt
    G04929303Courtesy of MAZDA MOTORS CORP.
  36. Remove the water pump.
    Fig 35: Locating Camshaft Position (CMP) Sensor
    G04929304Courtesy of MAZDA MOTORS CORP.
  37. Remove the camshaft position (CMP) sensor, cylinder head temperature (CHT) sensor and the spark plugs.
    Fig 36: Locating Valve Cover Bolt
    G04929305Courtesy 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 37: Locating Crankshaft Position (CKP) Sensor Bolt
    G04929306Courtesy of MAZDA MOTORS CORP.
  39. Remove the crankshaft position (CKP) sensor.
    Fig 38: Locating Crankshaft Pulley Bolt
    G04929125Courtesy 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 39: Identifying Camshaft Alignment Plate (303-465)
    G04929119Courtesy 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.
    NOTE:
    • The camshaft timing slots are offset. If the alignment plate SST  cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
  41. Install the alignment plate SST in the slots on the rear of both camshafts.
    Fig 40: Identifying Holding Fixture SST
    G04929130Courtesy of MAZDA MOTORS CORP.
  42. Install the holding fixture SST  and the crankshaft pulley / holding tool SST  .
    Fig 41: Identifying Crankshaft Pulley, Bolt And SST
    G04929310Courtesy 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 holding fixture SST  and the crankshaft pulley/ holding tool SST  .
    3. Remove the crankshaft pulley.
    Fig 42: Locating Front Cover Bolts
    G04929311Courtesy 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 43: Identifying Timing Chain Tensioner Plunger And Bolt
    G04929172Courtesy 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 44: Locating Timing Chain Guides Bolt
    G04929313Courtesy of MAZDA MOTORS CORP.
  46. Remove the timing chain guides.
    Fig 45: Locating Timing Chain Assembly
    G04929314Courtesy of MAZDA MOTORS CORP.
  47. Remove the timing chain assembly.
    Fig 46: Locating Camshaft Bolt
    G04929315Courtesy 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 47: Identifying Oil Pump Chain Tensioner And Guide
    G04929316Courtesy 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 48: Identifying Oil Pump Chain And Sprockets
    G04929317Courtesy 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 49: Identifying Camshaft Alignment Plate (303-465)
    G04929119Courtesy of MAZDA MOTORS CORP.
  51. Remove the camshaft alignment plate SST. 
    Fig 50: Identifying Camshaft Bearing Cap Bolts Loosening Sequence
    G04929120Courtesy 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.
  53. Remove the camshafts.
    Fig 51: Locating Cylinder Head Bolts
    G04929191Courtesy of MAZDA MOTORS CORP.
  54. Remove the bolts and the cylinder head.
  55. Remove the cylinder head gasket.
    Fig 52: Locating Cylinder Head Alignment Dowels
    G04929321Courtesy of MAZDA MOTORS CORP.
  56. Remove the cylinder head alignment dowels.
    Fig 53: Locating Bolts Of Oil Pan
    G04929322Courtesy of MAZDA MOTORS CORP.
  57. Remove the bolts and the oil pan.
    Fig 54: Locating Rear Main Oil Seal Bolts
    G04929323Courtesy of MAZDA MOTORS CORP.
  58. Remove the rear main oil seal.
    Fig 55: Locating Oil Pump Pickup Tube Bolts
    G04929324Courtesy of MAZDA MOTORS CORP.
  59. Remove the oil pump pickup tube and gasket.
    Fig 56: Locating Oil Pump Bolts
    G04929325Courtesy of MAZDA MOTORS CORP.
  60. Remove the oil pump assembly and gasket.
scientia non olet · About LEMON Manuals