Installation Note

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.

Fig 1: Installing Fan Drive Pulley

Courtesy of MAZDA MOTORS CORP.

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.
Clean and inspect the mounting surfaces of the engine and the front cover.

Fig 2: Locating Areas For Applying Silicone Gasket And Sealant
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.
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 3: Identifying Front Cover Bolt Tightening Sequence
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 4: Lower Retaining Bolt Torque With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Position the power steering pump and install the lower retaining bolt.

Fig 5: Locating PSP Switch Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Connect the PSP switch electrical connector.

Fig 6: Locating Water Pump Pulley Bolt
Courtesy of MAZDA MOTORS CORP.
Install the water pump pulley.
Tightening Torque:

20 Nm {2.0 kgf-m, 15 ft-lbf}

Fig 7: Belt Tensioner Bolt With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the belt tensioner.

Fig 8: Locating Crankshaft Pulley Bolt
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 9: Locating CKP Sensor 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 10: Locating Alignment Tool With Mounting Bolts With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Adjust the CKP sensor with the Alignment Tool, and tighten the mounting bolts.

Fig 11: Locating Crankshaft Position (CKP) Sensor Electrical Connector
Courtesy of MAZDA MOTORS CORP.
Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
Connect the battery ground cable. See BATTERY DISCONNECT