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Home >> Mazda >> 2002 >> B4000 Base, Standard >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Engine Mechanical - Overhaul >> Engine Disassembly/Assembly >> Disassembly Note

Disassembly Note

WARNING:
  • If the fuel rail is used as a leverage device, damage may occur to the fuel rail. Care must be taken when working around the fuel rail.
  1. Rotate the drive belt tensioner counterclockwise and remove the drive belt.
  2. Remove the bolts and position the accessory bracket aside.
    Fig 1: Removing Accessory Bracket
    G02821136Courtesy of MAZDA MOTORS CORP.
  3. Remove the generator mounting bracket.
    1. Remove the drive belt tensioner bolt.
    2. Remove the generator mounting bracket bolts.
    Fig 2: Removing Generator Mounting Bracket
    G02821137Courtesy of MAZDA MOTORS CORP.
  4. Disconnect the Throttle Position (TP) sensor electrical connector.
    Fig 3: Disconnecting Throttle Position Sensor
    G02821138Courtesy of MAZDA MOTORS CORP.
  5. Disconnect the Idle Air Control (IAC) valve electrical connector and disconnect the EGR valve vacuum hose.
    Fig 4: Disconnecting IAC Valve Electrical Connector & EGR Valve Vacuum Hose
    G02821139Courtesy of MAZDA MOTORS CORP.
  6. Loosen the fitting and disconnect the exhaust manifold-to-EGR valve tube.
    Fig 5: Disconnecting Exhaust Manifold-To-EGR Valve Tube
    G02821140Courtesy of MAZDA MOTORS CORP.
  7. Disconnect the ignition coil electrical connector.
    Fig 6: Disconnecting Ignition Coil Electrical Connector
    G02821141Courtesy of MAZDA MOTORS CORP.
  8. Disconnect the radio ignition interference capacitor electrical connector.
    Fig 7: Disconnecting Radio Ignition Interference Capacitor Electrical Connector
    G02821142Courtesy of MAZDA MOTORS CORP.
  9. Disconnect the EGR vacuum regulator.
    Fig 8: Disconnecting EGR Vacuum Regulator
    G02821143Courtesy of MAZDA MOTORS CORP.
    10. CAUTION:
    • Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
    Fig 9: Removing Spark Plug Wires
    G02821144Courtesy of MAZDA MOTORS CORP.
  10. Using spark plug wire remover SST 303-106, remove the spark plug wires from the spark plugs and all routing clips.
  11. Remove the bolts.
    Fig 10: Removing Ignition Coil Bracket Bolts
    G02821145Courtesy of MAZDA MOTORS CORP.
  12. Remove the bolt and the coil and the ignition wires.
    Fig 11: Removing Bolt, Coil & Ignition Wires
    G02821146Courtesy of MAZDA MOTORS CORP.
  13. Disconnect the vacuum hoses.
    Fig 12: Disconnecting Vacuum Hoses
    G02821147Courtesy of MAZDA MOTORS CORP.
  14. Detach and disconnect the electrical connector.
    Fig 13: Disconnecting Electrical Connector
    G02821148Courtesy of MAZDA MOTORS CORP.
  15. Remove the intake manifold bolts and lift up the intake manifold.
    Fig 14: Removing Intake Manifold
    G02821149Courtesy of MAZDA MOTORS CORP.
  16. Remove the heated PCV hose retainers and remove the heated PCV fitting.
    Fig 15: Removing Heated PCV Fitting
    G02821150Courtesy of MAZDA MOTORS CORP.
  17. Remove the intake manifold.
  18. Remove the bolts.
    Fig 16: Removing Bracket Bolts
    G02821151Courtesy of MAZDA MOTORS CORP.
  19. Detach the wiring harness retainer and remove the heater tube and bracket assembly.
    Fig 17: Detaching Wiring Harness Retainer
    G02821152Courtesy of MAZDA MOTORS CORP.
  20. Disconnect the Camshaft Position (CMP) sensor electrical connector.
    Fig 18: Disconnecting Camshaft Position sensor Electrical Connector
    G02821153Courtesy of MAZDA MOTORS CORP.
  21. Disconnect the differential pressure feedback EGR transducer.
    Fig 19: Disconnecting Differential Pressure Feedback EGR Transducer
    G02821154Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 20: Disconnecting Crankshaft Position Sensor Electrical Connector
    G02821155Courtesy of MAZDA MOTORS CORP.
  23. Disconnect the water temperature indicator sender unit and the Engine Coolant Temperature (ETC) sensor electrical connectors.
    Fig 21: Disconnecting Water Temperature Indicator Sender Unit & ETC Sensor Electrical Connectors
    G02821156Courtesy of MAZDA MOTORS CORP.
    24. NOTE:
    • The LH side is shown, the RH side is similar.
    Fig 22: Disconnecting Fuel Injector Electrical Connectors
    G02821157Courtesy of MAZDA MOTORS CORP.
  24. Disconnect the six fuel injector electrical connectors.
  25. Remove the engine control/fuel charging wiring.
    Fig 23: Removing Engine Control/Fuel Charging Wiring
    G02821158Courtesy of MAZDA MOTORS CORP.
  26. Disconnect the EGR valve-to-exhaust manifold tube from the exhaust manifold.
    Fig 24: Disconnecting EGR Valve-To-Exhaust Manifold Tube
    G02821159Courtesy of MAZDA MOTORS CORP.
  27. Remove the bolt and position the lower fuel line bracket aside.
    Fig 25: Removing Lower Fuel Line Bracket
    G02821160Courtesy of MAZDA MOTORS CORP.
  28. Remove the fuel rail.
    Fig 26: Removing Fuel Rail
    G02821161Courtesy of MAZDA MOTORS CORP.
  29. Remove the LH valve cover and the gasket.
    Fig 27: Removing LH Valve Cover
    G02821162Courtesy of MAZDA MOTORS CORP.
  30. Remove the RH valve cover and the gasket.
    Fig 28: Removing RH Valve Cover
    G02821163Courtesy of MAZDA MOTORS CORP.
  31. Remove the fuel injectors.
    Fig 29: Removing Fuel Injectors
    G02821164Courtesy of MAZDA MOTORS CORP.
  32. Remove the thermostat housing.
    1. Remove the bolts.
    2. Release the bypass hose clamp.
    Fig 30: Removing thermostat housing
    G02821165Courtesy of MAZDA MOTORS CORP.
  33. Remove the oil level indicator tube.
    Fig 31: Removing Oil Level Indicator Tube
    G02821166Courtesy of MAZDA MOTORS CORP.
  34. Remove the knock sensor.
    Fig 32: Removing Knock Sensor
    G02821167Courtesy of MAZDA MOTORS CORP.
  35. Remove the RH exhaust manifold and the gasket.
    Fig 33: Removing RH Exhaust Manifold
    G02821168Courtesy of MAZDA MOTORS CORP.
  36. Remove the LH exhaust manifold and the gasket.
    Fig 34: Removing LH Exhaust Manifold
    G02821169Courtesy of MAZDA MOTORS CORP.
  37. Remove the water pump.
    Fig 35: Removing Water Pump
    G02821170Courtesy of MAZDA MOTORS CORP.
  38. Remove the bolt.
    Fig 36: Removing Crankshaft Pulley Bolt
    G02821171Courtesy of MAZDA MOTORS CORP.
  39. Using Crankshaft Damper Remover SST 303-101 (or 49UN-01-0010), remove the crankshaft pulley.
    Fig 37: Removing Crankshaft Pulley
    G02821172Courtesy of MAZDA MOTORS CORP.
  40. Remove the RH hydraulic chain tensioner.
    Fig 38: Removing RH Hydraulic Chain Tensioner
    G02821173Courtesy of MAZDA MOTORS CORP.
    41. NOTE:
    • Mark each camshaft roller follower to make sure of its original position during reassembly.
    Fig 39: Removing Camshaft Roller Followers
    G02821174Courtesy of MAZDA MOTORS CORP.
  41. Using Valve Spring Compressor SST 303-581, remove the camshaft roller followers.
    42. CAUTION:
    • The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
    Fig 40: Removing RH Camshaft Sprocket Bolt
    G02821175Courtesy of MAZDA MOTORS CORP.
  42. Remove the RH camshaft sprocket bolt.
  43. Remove the camshaft sprocket from the camshaft and install a rubber band on the cassette to hold the chain and camshaft sprocket in place.
    Fig 41: Removing Camshaft Sprocket
    G02821176Courtesy of MAZDA MOTORS CORP.
  44. Remove the bolt.
    Fig 42: Removing Hydraulic Chain Tensioner Bolt
    G02821177Courtesy of MAZDA MOTORS CORP.
  45. Remove the LH hydraulic chain tensioner.
    Fig 43: Removing LH Hydraulic Chain Tensioner
    G02821178Courtesy of MAZDA MOTORS CORP.
  46. Remove the LH camshaft sprocket bolt.
    Fig 44: Removing LH Camshaft Sprocket Bolt
    G02821179Courtesy of MAZDA MOTORS CORP.
  47. Remove the camshaft sprocket from the camshaft and instal a rubber band on the cassette to hold the chain and camshaft sprocket in place.
    Fig 45: Removing Camshaft Sprocket From Camshaft
    G02821180Courtesy of MAZDA MOTORS CORP.
  48. Remove the bolt.
    Fig 46: Removing Bolt
    G02821181Courtesy of MAZDA MOTORS CORP.
  49. Remove the bolts in the sequence shown and remove the LH cylinder head.
    Fig 47: LH Cylinder Head Bolt Removal Sequence
    G02821182Courtesy of MAZDA MOTORS CORP.
  50. Remove the bolts in the sequence shown and remove the RH cylinder head.
    Fig 48: RH Cylinder Head Bolt Removal Sequence
    G02821183Courtesy of MAZDA MOTORS CORP.
  51. Remove the engine front cover.
    Fig 49: Removing Engine Front Cover
    G02821184Courtesy of MAZDA MOTORS CORP.
  52. Remove the oil pan.
    Fig 50: Removing Oil Pan
    G02821185Courtesy of MAZDA MOTORS CORP.
  53. Remove the oil pump screen cover and tube.
    Fig 51: Removing Oil Pump Screen Cover & Tube
    G02821186Courtesy of MAZDA MOTORS CORP.
  54. Remove the ladder frame bolts.
    Fig 52: Removing Ladder Frame Bolts
    G02821187Courtesy of MAZDA MOTORS CORP.
  55. Remove the ladder frame bolts.
    Fig 53: Removing Ladder Frame Bolts
    G02821188Courtesy of MAZDA MOTORS CORP.
  56. Remove the 15 bolts and the 2 nuts. Remove the ladder frame.
    Fig 54: Removing Ladder Frame
    G02821189Courtesy of MAZDA MOTORS CORP.
  57. Remove the oil pump.
    Fig 55: Removing Oil Pump
    G02821190Courtesy of MAZDA MOTORS CORP.
  58. Remove the oil filter.
  59. Remove the oil filter adapter.
    Fig 56: Removing Oil Filter Adapter
    G02821191Courtesy of MAZDA MOTORS CORP.
  60. Inspect and install new O-ring seals if necessary.
    Fig 57: Inspect O-ring Seals
    G02821192Courtesy of MAZDA MOTORS CORP.
  61. Remove the chain tensioner.
    Fig 58: Removing Chain Tensioner
    G02821193Courtesy of MAZDA MOTORS CORP.
  62. Remove the chain guide.
    Fig 59: Removing Chain Guide
    G02821194Courtesy of MAZDA MOTORS CORP.
  63. Remove the rear jackshaft plug.
    Fig 60: Removing Rear Jackshaft Plug
    G02821195Courtesy of MAZDA MOTORS CORP.
  64. Install the Rear Jackshaft Socket SST 303-634 at the rear of the jackshaft.
    Fig 61: Installing Rear Jackshaft Socket At Rear Of Jackshaft
    G02821196Courtesy of MAZDA MOTORS CORP.
  65. Loosen the front sprocket retaining bolt.
    Fig 62: Loosening Front Sprocket Retaining Bolt
    G02821197Courtesy of MAZDA MOTORS CORP.
  66. With the Rear Jackshaft Socket still in place, loosen the rear sprocket retaining bolt.
  67. Remove the Rear Jackshaft Socket.
    68. NOTE:
    • It may be required to hold the oil pump intermediate shaft, using an E-12 external TORX socket, in order to remove the bolts if bolts do not turn out easily at this time.
    Fig 63: Removing Front Sprocket Retaining Bolt
    G02821198Courtesy of MAZDA MOTORS CORP.
  68. Remove the front sprocket retaining bolt.
  69. Remove the Jackshaft sprocket and chain.
    Fig 64: Removing Jackshaft Sprocket & Chain
    G02821199Courtesy of MAZDA MOTORS CORP.
  70. Remove the bolt and front cassette with camshaft drive chain.
    Fig 65: Removing Front Cassette With Camshaft Drive Chain
    G02821200Courtesy of MAZDA MOTORS CORP.
  71. Remove the bolt and spacer.
    Fig 66: Removing Bolt & Spacer
    G02821201Courtesy of MAZDA MOTORS CORP.
  72. Remove the bolt and rear cassette with camshaft drive chain.
    Fig 67: Removing Rear Cassette With Camshaft Drive Chain
    G02821202Courtesy of MAZDA MOTORS CORP.
  73. Remove the oil pump drive.
    Fig 68: Removing Oil Pump Drive
    G02821203Courtesy of MAZDA MOTORS CORP.
  74. Remove the Jackshaft thrust plate.
    Fig 69: Removing Jackshaft Thrust Plate
    G02821204Courtesy of MAZDA MOTORS CORP.
  75. Remove the jackshaft.
    Fig 70: Removing Jackshaft
    G02821205Courtesy of MAZDA MOTORS CORP.
  76. On vehicles with a balance shaft, remove the balance shaft tensioner.
    1. Install a pin in the balance shaft tensioner.
    2. Remove the bolts.
    3. Remove the balance shaft tensioner.
    Fig 71: Removing Balance Shaft Tensioner
    G02821206Courtesy of MAZDA MOTORS CORP.
    77. NOTE:
    • DO NOT remove the balance shaft sprocket bolt.
    Fig 72: Removing Balance Shaft Chain & Crankshaft Sprocket
    G02821207Courtesy of MAZDA MOTORS CORP.
  77. On vehicles with a balance shaft, remove the balance shaft chain and crankshaft sprocket.
  78. On vehicles equipped with a balance shaft, remove the balance shaft.
    1. Remove the bolts.
    2. Remove the balance shaft.
    Fig 73: Removing Balance Shaft
    G02821208Courtesy of MAZDA MOTORS CORP.
  79. Using the cylinder ridge reamer SST 303-016 (T64L-6011-EA), remove the ridge and carbon deposits from the top of each cylinder.
    Fig 74: Removing Ridge & Carbon Deposits From Top Of Cylinder
    G02821209Courtesy of MAZDA MOTORS CORP.
  80. Remove the piston and connecting rod assemblies.
    1. Remove the connecting rod nuts.
    2. Remove the connecting rod cap.
    Fig 75: Removing Connecting Rod Nuts & Cap
    G02821210Courtesy of MAZDA MOTORS CORP.
  81. Install rubber hose pieces on the bolts to protect the crankshaft and remove the pistons.
    Fig 76: Installing Rubber Hose Pieces On Bolts
    G02821211Courtesy of MAZDA MOTORS CORP.
  82. Remove the main bearing cap bolts.
    Fig 77: Removing Main Bearing Cap Bolts
    G02821212Courtesy of MAZDA MOTORS CORP.
  83. Remove the crankshaft main bearing caps.
    Fig 78: Removing Crankshaft Main Bearing Caps
    G02821213Courtesy of MAZDA MOTORS CORP.
  84. Remove the crankshaft rear oil seal from the crankshaft.
    Fig 79: Removing Crankshaft Rear Oil Seal
    G02821214Courtesy of MAZDA MOTORS CORP.
  85. Remove the crankshaft.
    Fig 80: Removing Crankshaft
    G02821215Courtesy of MAZDA MOTORS CORP.
  86. Remove the crankshaft main bearings and the thrust bearing.
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