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Home >> Mazda >> 2002 >> B2300 Standard >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine Mechanical >> Engine Disassembly And Assembly >> Assembly Note

Assembly Note

WARNING: Failure to position the No. 1 piston at TDC can result in damage to the engine.
  1. Using the damper bolt, turn the crankshaft clockwise to position the No. 1 piston.
  2. Remove the plug bolt.
    Fig 1: Removing Plug Bolt
    G01168151Courtesy of MAZDA MOTORS CORP.
  3. Install the Engine Timing Peg (ST 303-507)  .
    Fig 2: Installing Engine Timing Peg
    G01168152Courtesy of MAZDA MOTORS CORP.
    4. NOTE: Clean the gasket surface with metal surface cleaner.
    Fig 3: Oil Pump Assembly Bolt Tightening Sequence
    G01168153Courtesy of MAZDA MOTORS CORP.
  4. Install a new gasket and the oil pump assembly. Tighten the bolts in the sequence shown in two stages.
    1. Stage 1: Tighten the bolts to 10 N.m (1.0 kgf-m, 80 lb-in).
    2. Stage 2: Tight the bolts to 23 N.m (2.3 kgf-m, 17 lb-ft).
    5. NOTE: Clean the gasket surface with a metal surface cleaner.
    Fig 4: Installing Oil Pump Pickup Tube
    G01168154Courtesy of MAZDA MOTORS CORP.
  5. Install a new oil pump pickup tube gasket and the pickup tube. Tighten the bolts in the sequence shown.
  6. Using the special tool, install the rear main oil seal.
    Fig 5: Installing Rear Main Oil Seal
    G01168155Courtesy of MAZDA MOTORS CORP.
  7. Tighten the rear main oil seal bolts in the sequence shown.
    Fig 6: Rear Main Oil Seal Bolt Tightening Sequence
    G01168156Courtesy of MAZDA MOTORS CORP.
    8. NOTE: Clean the gasket surface with metal surface cleaner.
    Fig 7: Oil Pan Bolt Tightening Sequence
    G01168157Courtesy of MAZDA MOTORS CORP.
  8. Install a new gasket and the oil pan. Tighten the bolts in the sequence shown.
  9. Install the cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
    Fig 8: Installing Cylinder Head Alignment Dowels
    G01168158Courtesy of MAZDA MOTORS CORP.
    10. NOTE: Clean the gasket surface with metal surface cleaner.
  10. Install a new cylinder head gasket.
  11. Clean the cylinder head gasket surface with metal surface cleaner.
  12. Apply silicone gasket and sealant to the locations shown.
    Fig 9: Applying Silicone Gasket & Sealant
    G01168159Courtesy of MAZDA MOTORS CORP.
    13. 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.
    Fig 10: Cylinder Head Bolt Tightening Sequence
    G01168160Courtesy of MAZDA MOTORS CORP.
  13. Install the cylinder head. Tighten the bolts in the sequence shown in five stage.
    1. Stage 1: Tighten the bolts to 5 N.m (0.5 kgf-m, 44 lb-in).
    2. Stage 2: Tighten the bolts to 15 N.m (1.5 kgf-m, 11 lb-ft).
    3. Stage 3: tighten the bolts to 45 N.m (4.5 kgf-m, 33 lb-ft).
    4. Stage 4: Tighten the bolts an additional 90 degrees (1/4 turn).
    5. Stage 5: Tighten the bolts an additional 90 degrees (1/4 turn).
    14. CAUTION: Install the camshafts with the alignment notches 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.
    Fig 11: Camshaft Bearing Cap Bolt Tightening Sequence
    G01168161Courtesy of MAZDA MOTORS CORP.
  14. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown in three stages.
    1. Stage 1: Tighten the camshaft bearing caps one turn at a time until tight.
    2. Stage 2: Tighten the bolts to 7 N.m (0.7 kgf-m, 62 lb-in).
    3. Stage 3: Tighten the bolts to 16 N.m (1.6 kgf-m, 12 lb-ft).
  15. Install the oil pump chain and sprockets.
    1. The crankshaft sprocket flange must be facing away from the engine block.
    Fig 12: Installing Oil Pump Chain & Sprockets
    G01168162Courtesy of MAZDA MOTORS CORP.
    16. NOTE: The oil pump chain sprocket must be held in place.
    Fig 13: Tighten the oil pump sprocket bolt
    G01168163Courtesy of MAZDA MOTORS CORP.
  16. Tighten the oil pump sprocket bolt.
  17. Install the oil pump chain guide and the shoulder bolt.
    Fig 14: Installing Oil Pump Chain Guide & Shoulder Bolt
    G01168164Courtesy of MAZDA MOTORS CORP.
  18. Install the oil pump chain tensioner. Hook the tensioner spring around the shoulder bolt.
    Fig 15: Installing Oil Pump Chain Tensioner
    G01168165Courtesy of MAZDA MOTORS CORP.
    19. NOTE: Sprockets must be turn freely on the camshafts.
    Fig 16: Installing Camshaft Sprockets
    G01168166Courtesy of MAZDA MOTORS CORP.
  19. Install the camshaft sprockets and the bolts. Do not tighten the sprocket bolts at this time.
    20. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.
    Fig 17: Compressing Timing Chain Tensioner Plunger
    G01168167Courtesy of MAZDA MOTORS CORP.
  20. Using the edge of a vise, compress the timing chain tensioner plunger.
  21. Using a small pick, push back and hold the ratchet mechanism.
    Fig 18: Holding Ratchet Mechanism
    G01168168Courtesy of MAZDA MOTORS CORP.
  22. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    Fig 19: Pushing Ratchet Arm Into Tensioner Housing
    G01168169Courtesy 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 20: Holding Ratchet Assembly & Plunger In
    G01168170Courtesy of MAZDA MOTORS CORP.
  24. Install the timing chain.
    Fig 21: Installing Timing Chain
    G01168171Courtesy of MAZDA MOTORS CORP.
  25. Install the timing chain guides.
    Fig 22: Installing Timing Chain Guides
    G01168172Courtesy of MAZDA MOTORS CORP.
  26. Install the timing chain tensioner. Remove the paper clip to apply tension to the timing chain.
    Fig 23: Installing Timing Chain Tensioner
    G01168173Courtesy of MAZDA MOTORS CORP.
  27. Install the Camshaft Alignment Plate (303-376)  in the timing slots on rear of both camshafts. Timing slots are offset from the centerline of the camshaft.
    Fig 24: Installing Camshaft Alignment Plate
    G01168174Courtesy 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.
    Fig 25: Tightening Camshaft Sprocket Bolts
    G01168175Courtesy of MAZDA MOTORS CORP.
  29. Clean the front cover gasket surface with metal surface cleaner.
  30. Apply a 2.5 mm beak of silicone gasket and sealant to the front cover.
    Fig 26: Applying Silicone Gasket & Sealant To Front Cover
    G01168176Courtesy of MAZDA MOTORS CORP.
  31. Apply silicone gasket and sealant to the locations shown.
    Fig 27: Applying Silicone Gasket & Sealant
    G01168177Courtesy of MAZDA MOTORS CORP.
    32. 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.
    Fig 28: Front Cover Bolt Tightening Sequence
    G01168178Courtesy of MAZDA MOTORS CORP.
  32. Install the front cover. Tighten the bolts in the sequence shown in three stages.
    1. Stage 1: Tighten the 8 mm bolts to 10 N.m (1.0 kgf-m, 89 lb-in).
    2. Stage 2: Tighten the 10 mm bolts to 25 N.m (2.5 kgf-m, 18 lb-ft).
    3. Stage 3: Tighten the 13 mm bolts to 48 N.m (4.8 kgf-m, 35 lb-ft).
    33. NOTE: Do not reuse the crankshaft pulley bolt.
    Fig 29: Installing Vibration Damper
    G01168179Courtesy of MAZDA MOTORS CORP.
  33. Install the vibration damper.
    • Install the vibration damper.
        NOTE: Rotate the vibration damper as necessary to align.
      1. Install the timing pin bolt through the vibration damper and into the front cover.
      2. Install the vibration damper bolt. Tighten the bolt in two stages.
        1. Stage 1: Tighten the bolt to 40 N.m (4.0 kgf-m, 30 lb-ft).
        2. Stage 2: Tighten the bolt and additional 90 degrees (1/4 turn).
      3. Remove the timing pin bolt.
  34. Remove the special tool from the side plug access hole.
  35. Install the side plug.
    Fig 30: Installing Side Plug
    G01168180Courtesy of MAZDA MOTORS CORP.
  36. Using the special tool, install the Crankshaft Position (CKP) sensor. The tool must engage a tooth of the vibration damper.
    Fig 31: Installing CKP Sensor
    G01168181Courtesy of MAZDA MOTORS CORP.
  37. Remove the Camshaft Alignment Plate.
    Fig 32: Removing Camshaft Alignment Plate
    G01168182Courtesy of MAZDA MOTORS CORP.
  38. Clean the valve cover gasket surface with metal surface cleaner.
  39. Apply silicone gasket and sealant to the locations shown.
    Fig 33: Applying Silicone Gasket & Sealant
    G01168183Courtesy of MAZDA MOTORS CORP.
    40. 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.
    Fig 34: Installing Valve Cover
    G01168184Courtesy of MAZDA MOTORS CORP.
  40. Install the valve cover.
  41. Install the following:
    • Camshaft Position (CMP) sensor.
    • Cylinder Head Temperature (CHT) sensor.
    • Spark plugs.
    Fig 35: Installing CMP, CHT Sensor & Spark Plugs
    G01168185Courtesy of MAZDA MOTORS CORP.
    42. NOTE: Clean the water pump gasket surface with metal surface cleaner.
    NOTE: Lubricate the water pump O-ring seal with MERPOL prior to assembly.
    Fig 36: Installing Water Pump
    G01168186Courtesy of MAZDA MOTORS CORP.
  42. Install the water pump.
  43. Install the water pump pulley.
    44. Fig 37: Installing Water Pump Pulley
    G01168187Courtesy of MAZDA MOTORS CORP.
  44. Install the fuel injection supply manifold and the ground strap.
    Fig 38: Installing Fuel Injection Supply Manifold & Ground Strap
    G01168188Courtesy of MAZDA MOTORS CORP.
  45. Install the left motor mount.
    Fig 39: Installing Left Motor Mount
    G01168189Courtesy of MAZDA MOTORS CORP.
    NOTE: The knock sensor must not touch the engine vent cover.
  46. Install the engine vent cover and the Knock Sensor (KS).
    Fig 40: Installing Engine Vent Cover & Knock Sensor
    G01168190Courtesy of MAZDA MOTORS CORP.
    NOTE: Clean the thermostat housing gasket surface with metal surface cleaner.
  47. Install a new gasket and the thermostat housing.
    Fig 41: Installing Thermostat Housing
    G01168191Courtesy of MAZDA MOTORS CORP.
  48. Install the bypass hose and the clamp.
    Fig 42: Installing Bypass Hose
    G01168192Courtesy of MAZDA MOTORS CORP.
  49. Install the ignition coil.
    Fig 43: Installing Ignition Coil
    G01168193Courtesy of MAZDA MOTORS CORP.
    50. NOTE: Apply silicone dielectric compound to the inside of the spark plug boots.
  50. Connect the spark plug wires to the spark plugs.
  51. Install the fuel charging wiring harness. Attach the fuel charging wiring harness to the valve cover studs.
    Fig 44: Installing Fuel Charging Wiring Harness
    G01168194Courtesy of MAZDA MOTORS CORP.
  52. Connect the ignition coil and the CHT sensor electrical connectors.
    Fig 45: Connecting Ignition Coil & CHT Sensor Electrical Connectors
    G01168195Courtesy of MAZDA MOTORS CORP.
  53. Connect the fuel injector electrical connectors. Attach the wiring harness pin-type retainers.
    Fig 46: Connecting Fuel Injector Electrical Connectors
    G01168196Courtesy of MAZDA MOTORS CORP.
  54. Install the intake manifold.
    Fig 47: Installing Intake Manifold
    G01168197Courtesy of MAZDA MOTORS CORP.
  55. Attach the vacuum line to the intake manifold. Secure the fuel line clip to the intake manifold.
    Fig 48: Attaching Vacuum Line
    G01168198Courtesy of MAZDA MOTORS CORP.
  56. Install the EGR tube.
    • Install the EGR tube bracket to the intake manifold.
    • Connect the EGR tube to the cylinder head.
    Fig 49: Installing EGR Tube
    G01168199Courtesy of MAZDA MOTORS CORP.
  57. Connect the EGR tube to the intake manifold.
    Fig 50: Connecting EGR Tube
    G01168200Courtesy of MAZDA MOTORS CORP.
  58. Install the engine wiring harness connector bracket.
    Fig 51: Installing Engine Wiring Harness Connector Bracket
    G01168201Courtesy of MAZDA MOTORS CORP.
  59. Attach the engine wiring harness pin-type retainers to the intake manifold.
  60. Connect the CMP sensor electrical connector and the PCV hose.
    Fig 52: Connecting CMP Sensor Electrical Connector & PCV Hose
    G01168202Courtesy of MAZDA MOTORS CORP.
  61. Connect the following electrical connectors:
    • Swirl control valve.
    • Knock sensor.
    • Electric thermostat.
    Fig 53: Connecting Swirl Control Valve, Knock Sensor & Electric Thermostat
    G01168203Courtesy of MAZDA MOTORS CORP.
  62. Connect the CKP sensor and wiring pin-type retainers.
    Fig 54: Connecting CKP Sensor
    G01168204Courtesy of MAZDA MOTORS CORP.
  63. Connect the swirl control valve electrical connector.
    Fig 55: Connecting Swirl Control Valve Electrical Connector
    G01168205Courtesy of MAZDA MOTORS CORP.
  64. Connect the following electrical connectors:
    • Manifold Absolute Pressure (MAP) sensor.
    • Throttle Position (TP) sensor.
    • Idle Air Control (IAC) valve.
    Fig 56: Connecting MAP, TP Sensor & IAC Valve
    G01168206Courtesy of MAZDA MOTORS CORP.
  65. Install the power steering pump and reservoir assembly.
    Fig 57: Installing Power Steering Pump & Reservoir Assembly
    G01168207Courtesy of MAZDA MOTORS CORP.
    66. NOTE: Clean the EGR valve gasket surface with metal surface cleaner.
    Fig 58: Installing EGR Valve
    G01168208Courtesy of MAZDA MOTORS CORP.
  66. Install a new gasket and the EGR valve. Connect the EGR electrical connector.
    67. NOTE: Clean the water outlet tube gasket surface with metal surface cleaner.
    Fig 59: Installing Water Outlet Tube
    G01168209Courtesy of MAZDA MOTORS CORP.
  67. Install a new gasket and the water outlet tube.
    • Tighten the bolts.
    • Connect the coolant hose.
    • Connect the Engine Coolant Temperature (ECT) sender electrical connector.
  68. Install the block heater.
    Fig 60: Installing Block Heater
    G01168210Courtesy of MAZDA MOTORS CORP.
  69. Install the exhaust manifold and gasket.
    Fig 61: Installing Exhaust Manifold
    G01168211Courtesy of MAZDA MOTORS CORP.
  70. Install the coolant tube assembly.
    Fig 62: Installing Coolant Tube Assembly
    G01168212Courtesy of MAZDA MOTORS CORP.
  71. Connect the following:
    • Coolant hose to the thermostat.
    • Coolant hose to EGR tube.
    Fig 63: Connecting Coolant Hoses
    G01168213Courtesy of MAZDA MOTORS CORP.
  72. Install the right motor mount.
    Fig 64: Installing Right Motor Mount
    G01168214Courtesy of MAZDA MOTORS CORP.
  73. Install the accessory bracket.
    Fig 65: Installing Accessory Bracket
    G01168215Courtesy of MAZDA MOTORS CORP.
  74. Install the A/C compressor.
    Fig 66: Installing A/C Compressor
    G01168216Courtesy of MAZDA MOTORS CORP.
    NOTE: Lubricate the O-ring seal with antifreeze.
  75. Install the water outlet tube.
    Fig 67: Installing Water Outlet Tube
    G01168217Courtesy of MAZDA MOTORS CORP.
    76. NOTE: Lubricate the O-ring seal with clean engine oil.
    Fig 68: Installing Engine Oil Level Indicator Assembly
    G01168218Courtesy of MAZDA MOTORS CORP.
  76. Install the engine oil level indicator assembly.
  77. Install the drive belt.
    Fig 69: Installing Drive Belt
    G01168219Courtesy of MAZDA MOTORS CORP.
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