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Home >> Mazda >> 2007 >> B3000 Base, Automatic >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine Mechanical - Overhaul >> Engine Disassembly/Assembly >> Assembly Note

Assembly Note

  1. Install the upper crankshaft main bearings.
    Fig 1: Installing Upper Crankshaft Main Bearings
    G03312242Courtesy of MAZDA MOTORS CORP.
    2. NOTE:
    • Lubricate the crankshaft journals and the crankshaft main bearings with clean engine oil.
    Fig 2: Installing Crankshaft
    G03312243Courtesy of MAZDA MOTORS CORP.
  2. Install the crankshaft.
  3. Install the crankshaft rear main oil seal.
    1. Lubricate the outer lips and the inner seal on the crankshaft rear oil seal.
    2. Install the crankshaft rear oil seal using Rear Main Seal Installer SST 49 UN01 064  . Alternate bolt tightening to seat seal properly.
    Fig 3: Installing Crankshaft Rear Oil Seal
    G04307410
  4. Apply two dots of gasket eliminator or equivalent between the rear bearing cap and the cylinder block.
    Fig 4: Applying Two Dots Of Gasket Eliminator
    G03312245Courtesy of MAZDA MOTORS CORP.
  5. Install the lower crankshaft main bearings.
    Fig 5: Installing Lower Crankshaft Main Bearings
    G03312246Courtesy of MAZDA MOTORS CORP.
  6. Wedge a large screwdriver at the location shown to hold the crankshaft forward until all the bolts are tightened.
    Fig 6: Locating Screwdriver Insertion Location
    G03312247Courtesy of MAZDA MOTORS CORP.
  7. Install the main bearing caps.
    Fig 7: Installing Main Bearing Caps
    G03312248Courtesy of MAZDA MOTORS CORP.
  8. Install the bolts.
    1. Tighten the bolts in pairs.
    2. For crankshaft and crankshaft bearing component tests, refer to CRANKSHAFT INSPECTION  and BEARING INSPECTION .
    Fig 8: Installing Main Bearing Cap Bolts With Torque Specifications
    G03312249Courtesy of MAZDA MOTORS CORP.
  9. If removed, install the camshaft bearings.
    • Use the Cam Bearing Service Set SST 303-017 (T65L-6250-A)  or equivalent.
    Fig 9: Installing Camshaft Bearings
    G03312250Courtesy of MAZDA MOTORS CORP.
    10. NOTE:
    • Lubricate the camshaft and the camshaft bearings with clean engine oil.
    Fig 10: Installing Camshaft
    G03312251Courtesy of MAZDA MOTORS CORP.
  10. Install the camshaft.
  11. Install the camshaft retainer.
    Fig 11: Installing Camshaft Retainer With Torque Specifications
    G03312252Courtesy of MAZDA MOTORS CORP.
  12. Inspect camshaft endplay. Refer to CAMSHAFT INSPECTION .
  13. Align timing marks.
    Fig 12: Aligning Timing Marks
    G03312253Courtesy of MAZDA MOTORS CORP.
  14. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
    Fig 13: Installing Timing Chain, Camshaft Sprocket & Crankshaft Sprocket Assembly
    G03312254Courtesy of MAZDA MOTORS CORP.
  15. Install the bolt.
    Fig 14: Installing Camshaft Sprocket Bolt With Torque Specifications
    G03312255Courtesy of MAZDA MOTORS CORP.
    16. NOTE:
    • Lubricate the piston and connecting rod assemblies with clean engine oil.
    Fig 15: Installing Piston & Connecting Rod Assemblies
    G03312256Courtesy of MAZDA MOTORS CORP.
  16. Install the piston and connecting rod assemblies.
    • Use a piston ring compressor.
    17. NOTE:
    • Lubricate the connecting rod bearings with clean engine oil.
  17. Install the connecting rod bearings.
  18. Install the connecting rod caps and nuts.
    1. Tighten the nuts in pairs.
    Fig 16: Installing Connecting Rod Caps And Nuts With Torque Specifications
    G03312257Courtesy of MAZDA MOTORS CORP.
  19. Install the oil pump.
    Fig 17: Installing Oil Pump With Torque Specifications
    G03312258Courtesy of MAZDA MOTORS CORP.
    20. NOTE:
    • Lubricate the valve tappets with clean engine oil.
    Fig 18: Installing Valve Tappets
    G03312259Courtesy of MAZDA MOTORS CORP.
  20. Install the valve tappets.
  21. Install the valve tappet guide plates.
    Fig 19: Installing Valve Tappet Guide Plates
    G03312260Courtesy of MAZDA MOTORS CORP.
  22. Install the valve tappet guide plate retainer.
    Fig 20: Installing Valve Tappet Guide Plate Retainer With Torque Specifications
    G03312261Courtesy of MAZDA MOTORS CORP.
  23. Install the cylinder head gaskets.
    Fig 21: Installing Cylinder Head Gaskets
    G03312262Courtesy of MAZDA MOTORS CORP.
  24. Install the cylinder heads.
    Fig 22: Installing Cylinder Head
    G03312263Courtesy of MAZDA MOTORS CORP.
  25. Install the bolts. Tighten the bolts in the sequence shown in four steps.
    1. Tighten the bolts to 80 N.m (59 ft.lbf).
    2. Loosen the bolts one full turn.
    3. Tighten to 45-55 N.m (34-40 ft.lbf).
    4. Tighten to 85-99 N.m (63-73 ft.lbf).
    Fig 23: Cylinder Head Bolt Tightening Sequence
    G03312264Courtesy of MAZDA MOTORS CORP.
  26. Install the oil filter.
    Fig 24: Installing Oil Filter
    G03312265Courtesy of MAZDA MOTORS CORP.
  27. Install the oil level indicator tube.
    Fig 25: Installing Oil Level Indicator Tube With Torque Specifications
    G03312266Courtesy of MAZDA MOTORS CORP.
  28. Install the EGR valve to exhaust manifold tube.
    Fig 26: Installing EGR Valve To Exhaust Manifold Tube With Torque Specifications
    G03312267Courtesy of MAZDA MOTORS CORP.
  29. Install the engine front cover gasket and the engine front cover.
    Fig 27: Installing Engine Front Cover Gasket
    G03312268Courtesy of MAZDA MOTORS CORP.
  30. Apply pipe sealant with on the bolts to be installed in the locations shown.
    Fig 28: Applying Pipe Sealant
    G03312269Courtesy of MAZDA MOTORS CORP.
  31. Install the bolts.
    1. Tighten the bolts in the sequence shown.
    Fig 29: Installing Engine Front Cover Bolts With Torque Specifications
    G03312270Courtesy of MAZDA MOTORS CORP.
  32. Install the CKP sensor.
    Fig 30: Installing CKP Sensor With Torque Specifications
    G03312271Courtesy of MAZDA MOTORS CORP.
  33. Apply four beads of silicone as shown.
    Fig 31: Silicone Application Areas
    G03312272Courtesy of MAZDA MOTORS CORP.
  34. Install the oil pan gasket.
    Fig 32: Installing Oil Pan Gasket
    G03312273Courtesy of MAZDA MOTORS CORP.
  35. Install the oil pan and hand-start the bolts.
    Fig 33: Installing Oil Pan
    G03312274Courtesy of MAZDA MOTORS CORP.
  36. Install the oil pan bolts.
    1. Tighten the bolts in four steps.
      • Tighten the four corner bolts to 10-14 N.m (89-123 in.lbf).
      • Tighten the remaining bolts to 10-14 N.m (89-123 in.lbf).
      • Loosen all the bolts one turn.
      • Tighten all the bolts to 10-14 N.m (89-123 in.lbf).
    Fig 34: Tightening Oil Pan Bolts
    G03312275Courtesy of MAZDA MOTORS CORP.
  37. Install the camshaft synchronizer. Refer to CAMSHAFT .
  38. Apply four beads of Silicone Rubber.
    Fig 35: Silicone Rubber Application Areas
    G03312276Courtesy of MAZDA MOTORS CORP.
  39. Install the intake manifold gaskets and end seals.
    Fig 36: Installing Intake Manifold Gaskets & End Seals
    G03312277Courtesy of MAZDA MOTORS CORP.
  40. Install the lower intake manifold.
    1. Tighten the bolts in the sequence shown.
    Fig 37: Intake Manifold Torque Sequence With Torque Specifications
    G03312278Courtesy of MAZDA MOTORS CORP.
  41. Install the push rods and the rocker arms.
    1. Install the push rods.
    2. Install the rocker arms.
    3. Tighten the rocker arm bolts.
    Fig 38: Installing Push Rods And Rocker Arms With Torque Specifications
    G03312279Courtesy of MAZDA MOTORS CORP.
  42. Apply a bead of silicone to the four intake-to-cylinder head seams.
    Fig 39: Applying Silicone To Intake-To-Cylinder Head Seams
    G03312280Courtesy of MAZDA MOTORS CORP.
  43. If removed, install the valve cover gaskets.
    Fig 40: Installing Valve Cover Gaskets
    G03312281Courtesy of MAZDA MOTORS CORP.
  44. Install the valve covers.
    1. Tighten the bolts in the sequence shown.
    Fig 41: Installing Valve Covers With Torque Specifications
    G03312282Courtesy of MAZDA MOTORS CORP.
  45. Position the engine harness and connect:
    • The camshaft synchronizer.
    • The fuel injectors.
    • The water temperature indicator sender unit.
    • The engine harness.
    Fig 42: Connecting Engine Harness Connectors
    G03312283Courtesy of MAZDA MOTORS CORP.
  46. Install the intake manifold upper gasket.
    Fig 43: Installing Intake Manifold Upper Gasket
    G03312284Courtesy of MAZDA MOTORS CORP.
  47. Install the PCV valve.
  48. Install the upper intake manifold.
    1. Install the three bolts and the three stud bolts.
    2. Tighten the bolts in the sequence shown in two steps.
    3. Tighten to 20 N.m (14 ft.lbf)
    4. Tighten to 25 N.m (18 ft.lbf)
    Fig 44: Upper Intake Manifold Bolt Tightening Sequence
    G03312285Courtesy of MAZDA MOTORS CORP.
  49. Connect the engine harness to:
    • The Idle Air Control (IAC) valve.
    • The Throttle Position (TP) sensor.
    • The DPFE transducer.
    Fig 45: Connecting IAC valve, TP Sensor & DPFE Transducer Connectors
    G03312286Courtesy of MAZDA MOTORS CORP.
  50. Using the Vibration Damper and Seal Replacer SST 303-175 (T82L-6316-A)  or equivalent, install the crankshaft damper.
    Fig 46: Installing Crankshaft Damper
    G03312287Courtesy of MAZDA MOTORS CORP.
  51. Install the bolt.
    Fig 47: Installing Crankshaft Damper Bolt With Torque Specifications
    G03312288Courtesy of MAZDA MOTORS CORP.
  52. Install the crankshaft vibration damper and the bolts.
    Fig 48: Installing Crankshaft Vibration Damper With Torque Specifications
    G03312289Courtesy of MAZDA MOTORS CORP.
  53. Install the water pump pulley and the bolts.
    Fig 49: Installing Water Pump Pulley With Torque Specifications
    G03312290Courtesy of MAZDA MOTORS CORP.
  54. Install the generator mounting bracket and the bolts.
    Fig 50: Installing Generator Mounting Bracket With Torque Specifications
    G03312291Courtesy of MAZDA MOTORS CORP.
  55. Install the nuts.
    Fig 51: Installing Support Bracket Nuts With Torque Specifications
    G03312292Courtesy of MAZDA MOTORS CORP.
  56. Connect the engine harness to:
    • The ignition coil.
    • The radio ignition interference capacitor.
    • The EGR vacuum regulator solenoid.
    • The vacuum line from the EGR vacuum regulator solenoid.
    Fig 52: Connecting Engine Harness Connectors
    G03312293Courtesy of MAZDA MOTORS CORP.
  57. Connect the vacuum line.
    Fig 53: Connecting Vacuum Line
    G03312294Courtesy of MAZDA MOTORS CORP.
  58. Connect the spark plug wires.
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