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Valve Clearance Adjustment

WARNING: This page is about a different car, the 2005 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the negative battery cable.
  2. Remove the tire (RH).
  3. Remove the splash shield (RH).
  4. Remove the plug hole plate.

    (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)

  5. Remove the high-tension lead. (if equipped) (See HIGH-TENSION LEAD REMOVAL/INSTALLATION [L3 (WITH DEI SYSTEM)] .)
  6. Remove the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION .)
  7. Remove the oil control valve (OCV) connector.
  8. Remove the ventilation hose.
  9. Remove the cylinder head cover.
  10. Remove the drive belt. (See DRIVE BELT REPLACEMENT .)
  11. Remove the front drive shaft (RH) from the joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION [L3] .)
  12. Remove the engine front cover lower blind plug.
    Fig 1: Removing Engine Front Cover Lower Blind Plug
    G03643606Courtesy of MAZDA MOTORS CORP.
  13. Remove the engine front cover upper blind plug.
  14. Remove the cylinder block lower blind plug.
    Fig 2: Removing Engine Front Cover Upper Blind Plug
    G03643607Courtesy of MAZDA MOTORS CORP.
  15. Install the SST  as shown in the figure.
  16. Rotate the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is contacting the SST  ).
  17. Loosen the timing chain.
    Fig 3: Installing SST
    G03643608Courtesy of MAZDA MOTORS CORP.
    1. Unlock the chain tensioner ratchet using a suitable screwdriver or equivalent tool.
    2. Rotate the exhaust camshaft clockwise using a suitable wrench on the cast hexagon and loosen a timing chain.
      Fig 4: Rotating Exhaust Camshaft
      G03643609Courtesy of MAZDA MOTORS CORP.
    3. Placing the suitable bolt (M6 X 1.0 length 25-35 mm {0.99-1.37 in})  at the engine front cover upper blind plug, secure the chain guide at the position where the tension is released.
  18. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the illustration.
    Fig 5: Holding Exhaust Camshaft Using Suitable Wrench
    G03643610Courtesy of MAZDA MOTORS CORP.
  19. Remove the exhaust camshaft sprocket.
    Fig 6: Removing Exhaust Camshaft Sprocket
    G03643611Courtesy of MAZDA MOTORS CORP.
  20. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure.
    NOTE:
    • The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly. When removed, keep the caps with the cylinder head from where they were removed. Do not mix the caps.
      Fig 7: Camshaft Cap Bolt Removal Sequence
      G03643612Courtesy of MAZDA MOTORS CORP.
  21. Remove the camshaft.
  22. Remove the tappet.
  23. Select proper adjustment shim.

    New adjustment shim 

    = 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] 

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

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

  24. Install the camshaft and No. 1 cylinder aligned with the TDC position.
  25. Tighten the camshaft cap bolt in the following two steps.
    1. Tighten to 5.0-9.0 N.m {51.0-91.7 kgf.cm, 44.3-79.6 in.lbf}. 
    2. Tighten to 14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf}. 
      Fig 8: Camshaft Cap Bolt Tightening Sequence
      G03643613Courtesy of MAZDA MOTORS CORP.
  26. 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 9: Installing Exhaust Camshaft Sprocket
      G03643614Courtesy of MAZDA MOTORS CORP.
  27. Install the SST  to the camshaft as shown in the figure.
  28. Remove the (M6 X 1.0 length 25mm-35mm {0.99-1.37in})  bolt from the engine front cover to apply tension to the timing chain.
  29. Turn the crankshaft clockwise until the crankshaft is in the No. 1 cylinder TDC position (until the balance weight is contacting to the SST  ).
    Fig 10: Installing SST
    G03643615Courtesy of MAZDA MOTORS CORP.
  30. Hold the exhaust camshaft using a suitable wrench on the cast hexagon as shown in the figure.
  31. Tighten the exhaust camshaft sprocket lock bolt.

    Tightening torque 

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

    Fig 11: Holding Exhaust Camshaft Using Suitable Wrench
    G03643616Courtesy of MAZDA MOTORS CORP.
  32. Remove the SST  from the camshaft.
  33. Remove the SST  from the block lower blind plug.
  34. Rotate the crankshaft two times clockwise until the crankshaft is in the TDC position, reinstall the SSTs  to the camshaft and cylinder block, and inspect the valve timing.
    • If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step  16.
  35. Apply silicone sealant to the engine front cover upper blind plug.
  36. 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 12: Installing Engine Front Cover Upper Blind Plug
    G03643617Courtesy of MAZDA MOTORS CORP.
  37. 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 13: Installing Cylinder Block Lower Blind Plug
    G03643618Courtesy of MAZDA MOTORS CORP.
  38. Install the 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 14: Installing New Engine Front Cover Lower Blind Plug
    G03643619Courtesy of MAZDA MOTORS CORP.
  39. Connect the front drive shaft (RH) and the joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION [L3] .)
  40. Install the drive belt. (See DRIVE BELT REPLACEMENT .)
  41. Install the cylinder head cover. (See CYLINDER HEAD COVER INSTALLATION NOTE .)
  42. Install the ventilation hose.
  43. Install the oil control valve (OCV) connector.
  44. Install the high-tension lead. (See HIGH-TENSION LEAD REMOVAL/INSTALLATION [L3 (WITH DEI SYSTEM)] .)
  45. Install the spark plugs. (See SPARK PLUG REMOVAL/INSTALLATION .)
  46. Install the plug hole plate.

    (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)

  47. Install the splash shield (RH).
  48. Install the tire (RH).
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