Valve Clearance Adjustment

WARNING: This page does not describe the selected car, but rather 22 other vehicles, including the 2009 Mazda B2300, 2009 Mazda 5, 2008 Mazda Tribute, 2008 Mazda B2300, and 2008 Mazda 5. However, it is still accessible from the selected car via links, so may be relevant.

Remove the engine front cover lower blind plug.
Remove the engine front cover upper blind plug.

Fig 1: Identifying Upper & Lower Blind Plug
Courtesy of MAZDA MOTORS CORP.
Remove the cylinder block lower blind plug.

CAUTION:

Removal of this SST is extremely important. If you crank the engine with this SST installed, the cylinder block will be damaged.

Fig 2: Installing SST

Courtesy of MAZDA MOTORS CORP.

Install the SST as shown in the figure.
Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
Loosen the timing chain.
1. Using a suitable screwdriver or equivalent tool, unlock the chain tensioner ratchet.
2. Turn the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen the timing chain.
3. Placing the suitable bolt (M6 x 1.0 Length 25-35 mm {0.9-1.3 in}) at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
  
  Fig 3: Loosening Timing Chain Tension
  Courtesy of MAZDA MOTORS CORP.
Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.

Fig 4: Removing Exhaust Camshaft Sprocket Bolt
Courtesy of MAZDA MOTORS CORP.
Remove the exhaust camshaft sprocket.

Fig 5: Removing Exhaust Camshaft Sprocket
Courtesy of MAZDA MOTORS CORP.

NOTE:

The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.

Fig 6: Camshaft Cap Bolt Loosening Sequence

Courtesy of MAZDA MOTORS CORP.

Loosen the camshaft cap bolts in several passes in the order shown in the figure.
Remove the camshaft.
Remove the tappet.
Select proper adjustment shim.
New Adjustment Shim
1. = Removed Shim Thickness + Measured Valve Clearance - Standard Valve Clearance (IN: 0.25 mm {0.0098 in}, EX: 0.30 mm {0.0118 in})
Standard [Engine Cold]
1. IN: 0.22-0.28 mm {0.0087-0.0110 in}
2. EX: 0.27-0.33 mm {0.0106-0.0130 in}
Install the camshaft with No.1 cylinder aligned with the TDC position.
Tighten the camshaft cap bolt using the following two steps.
Tightening Torque
1. (1) 5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.5 in.lbf}
2. (2) 14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf}
  
  Fig 7: Camshaft Cap Bolt Tightening Sequence
  Courtesy of MAZDA MOTORS CORP.
Install the exhaust camshaft sprocket.
NOTE:
- Do not tighten the bolt for the camshaft sprocket during this step. First confirm the valve timing, then tighten the bolt.
Fig 8: Installing Exhaust Camshaft Sprocket
Courtesy of MAZDA MOTORS CORP.
Install the SST to the camshaft as shown in the figure.

Fig 9: Installing Camshaft SST
Courtesy of MAZDA MOTORS CORP.
Remove the M6 x 1.0 bolt from the engine front cover to apply tension to the timing chain.
Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.
Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
Tighten the exhaust camshaft sprocket lock bolt.
Tightening Torque
1. 69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf}
Remove the SST from the camshaft.
Remove the SST from the block lower blind plug.
Rotate the crankshaft clockwise two turns until the TDC position.
- If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 14.
Install the new engine front cover upper blind plug.
Tightening Torque
1. 8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf}
  
  Fig 11: Installing Engine Front Cover Upper Blind Plug
  Courtesy of MAZDA MOTORS CORP.
Install the cylinder block lower blind plug.
Tightening Torque
1. 18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf}
  
  Fig 12: Installing Cylinder Block Lower Blind Plug
  Courtesy of MAZDA MOTORS CORP.
Install the new engine front cover lower blind plug.
Tightening Torque
1. 10-14 N.m {1.1-1.4 kgf.m, 7.4-10.3 ft.lbf}
  
  Fig 13: Installing Engine Front Cover Lower Blind Plug
  Courtesy of MAZDA MOTORS CORP.