LEMON Manuals: Even more car manuals for everyone
Home >> Mazda >> 2007 >> B3000 Base, Automatic >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine Mechanical - Overhaul >> Engine Disassembly/Assembly >> Disassembly Note

Disassembly Note

  1. Disconnect the spark plug wires.
  2. Disconnect the vacuum line.
    Fig 1: Disconnecting Vacuum Line
    G03312191Courtesy of MAZDA MOTORS CORP.
  3. Disconnect the engine harness from:
    • The ignition coil.
    • The radio ignition interference capacitor.
    • The EGR vacuum regulator solenoid.
    • The vacuum line from the EGR vacuum regulator solenoid.
    Fig 2: Disconnecting Engine Harness
    G03312192Courtesy of MAZDA MOTORS CORP.
  4. Remove the nuts.
    Fig 3: Removing Coil Mounting Bracket Nuts
    G03312193Courtesy of MAZDA MOTORS CORP.
  5. Remove the bolts and the generator mounting bracket.
    Fig 4: Removing Generator Mounting Bracket Bolts
    G03312194Courtesy of MAZDA MOTORS CORP.
  6. Remove the bolt and nut.
    Fig 5: Removing Bolt & Nut
    G03312195Courtesy of MAZDA MOTORS CORP.
  7. Remove the bolts and the A/C compressor mounting bracket.
    Fig 6: Removing A/C Compressor Mounting Bracket
    G03312196Courtesy of MAZDA MOTORS CORP.
  8. Remove the bolts and the water pump pulley.
    Fig 7: Removing Water Pump Pulley With Torque Specifications
    G03312197Courtesy of MAZDA MOTORS CORP.
  9. Remove the bolts and the crankshaft pulley.
    Fig 8: Removing Crankshaft Pulley
    G03312198Courtesy of MAZDA MOTORS CORP.
  10. Remove the crankshaft damper bolt.
    Fig 9: Removing Crankshaft Damper Bolt
    G03312199Courtesy of MAZDA MOTORS CORP.
  11. Using Crankshaft Damper Remover SST 303-009 (T58P-6316-D)  or equivalent, remove the crankshaft damper.
    Fig 10: Removing Crankshaft Damper
    G03312200Courtesy of MAZDA MOTORS CORP.
  12. Disconnect the engine harness from:
    • The Idle Air Control (IAC) valve.
    • The Throttle Position (TP) sensor.
    • The DPFE sensor.
    Fig 11: Disconnecting IAC Valve, TP Sensor & DPFE Sensor Connectors
    G03312201Courtesy of MAZDA MOTORS CORP.
  13. Remove the six bolts and upper intake manifold.
    Fig 12: Removing Upper Intake Manifold
    G03312202Courtesy of MAZDA MOTORS CORP.
  14. Remove the Positive Crankcase Ventilation (PCV) valve.
    Fig 13: Removing PCV Valve
    G03312203Courtesy of MAZDA MOTORS CORP.
  15. Remove the intake manifold upper gasket.
    Fig 14: Removing Intake Manifold Upper Gasket
    G03312204Courtesy of MAZDA MOTORS CORP.
  16. Disconnect the engine harness from:
    • The Engine Coolant Temperature (ECT) sensor.
    • The water temperature indicator sender unit.
    • The fuel injectors.
    • The camshaft synchronizer.
    Fig 15: Disconnecting Engine Harness
    G03312205Courtesy of MAZDA MOTORS CORP.
  17. Remove the valve covers.
    Fig 16: Removing Valve Covers
    G03312206Courtesy of MAZDA MOTORS CORP.
  18. If required, remove the valve cover gaskets.
    Fig 17: Removing Valve Cover Gaskets
    G03312207Courtesy of MAZDA MOTORS CORP.
  19. Clean the sealing surfaces.
    Fig 18: Identifying Sealing Surfaces
    G03312208Courtesy of MAZDA MOTORS CORP.
  20. Remove the rocker arms and the push rods.
    Fig 19: Removing Rocker Arms
    G03312209Courtesy of MAZDA MOTORS CORP.
  21. Remove the eight bolts and lower intake manifold.
    Fig 20: Removing Lower Intake Manifold
    G03312210Courtesy of MAZDA MOTORS CORP.
  22. Remove the intake manifold gaskets and end seals.
    Fig 21: Removing Intake Manifold Gaskets & End Seals
    G03312211Courtesy of MAZDA MOTORS CORP.
  23. Clean the surface.
    Fig 22: Cleaning Gasket & Seal Surfaces
    G03312212Courtesy of MAZDA MOTORS CORP.
  24. Remove the camshaft synchronizer. Refer to CAMSHAFT .
  25. Remove the bolts and oil pan.
    Fig 23: Removing Oil Pan
    G03312213Courtesy of MAZDA MOTORS CORP.
  26. Remove the oil pan gasket.
    Fig 24: Removing Oil Pan Gasket
    G03312214Courtesy of MAZDA MOTORS CORP.
  27. Clean the surfaces.
    Fig 25: Cleaning Oil Pan Sealing Surfaces
    G03312215Courtesy of MAZDA MOTORS CORP.
  28. Remove the Crankshaft Position (CKP) sensor.
    Fig 26: Removing CKP sensor
    G03312216Courtesy of MAZDA MOTORS CORP.
  29. Remove the front cover bolts and engine front cover.
    Fig 27: Removing Engine Front Cover
    G03312217Courtesy of MAZDA MOTORS CORP.
  30. Remove the engine front cover gasket.
    Fig 28: Removing Engine Front Cover Gasket
    G03312218Courtesy of MAZDA MOTORS CORP.
  31. Clean the sealing surfaces.
    Fig 29: Cleaning Engine Front Cover Sealing Surfaces
    G03312219Courtesy of MAZDA MOTORS CORP.
  32. Remove the EGR valve to exhaust manifold tube.
    Fig 30: Removing EGR Valve To Exhaust Manifold Tube
    G03312220Courtesy of MAZDA MOTORS CORP.
  33. Remove the oil level indicator tube.
    Fig 31: Removing Oil Level Indicator Tube
    G03312221Courtesy of MAZDA MOTORS CORP.
  34. Remove the oil filter.
    Fig 32: Removing Oil Filter
    G03312222Courtesy of MAZDA MOTORS CORP.
  35. Remove the bolts.
    Fig 33: Removing Cylinder Head Bolts
    G03312223Courtesy of MAZDA MOTORS CORP.
  36. Remove the cylinder heads.
    Fig 34: Removing Cylinder Heads
    G03312224Courtesy of MAZDA MOTORS CORP.
  37. Remove the cylinder head gaskets.
    Fig 35: Removing Cylinder Head Gasket
    G03312225Courtesy of MAZDA MOTORS CORP.
  38. Remove the valve tappet guide plate retainer.
    Fig 36: Removing Valve Tappet Guide Plate Retainer
    G03312226Courtesy of MAZDA MOTORS CORP.
  39. Remove the valve tappet guide plates.
    Fig 37: Removing Valve Tappet Guide Plates
    G03312227Courtesy of MAZDA MOTORS CORP.
    40. NOTE:
    • The valve tappets are positional. Identify each valve tappet for installation in the original position.
    Fig 38: Removing Valve Tappets
    G03312228Courtesy of MAZDA MOTORS CORP.
  40. Remove the valve tappets.
  41. Align the timing marks.
    Fig 39: Aligning Timing Marks
    G03312229Courtesy of MAZDA MOTORS CORP.
  42. Remove the bolt.
    Fig 40: Removing Camshaft Pulley Bolt
    G03312230Courtesy of MAZDA MOTORS CORP.
  43. Remove the timing sprockets and timing chain as an assembly.
    Fig 41: Removing Timing Sprockets & Timing Chain
    G03312231Courtesy of MAZDA MOTORS CORP.
  44. Remove the camshaft retainer.
    Fig 42: Removing Camshaft Retainer
    G03312232Courtesy of MAZDA MOTORS CORP.
  45. Remove the camshaft.
    Fig 43: Removing Camshaft
    G03312233Courtesy of MAZDA MOTORS CORP.
  46. If required, remove the camshaft bearings.
    • Use the Camshaft Bearing Set SST 303-017 (T65L-6250-A)  or equivalent.
    Fig 44: Removing Camshaft Bearings
    G03312234Courtesy of MAZDA MOTORS CORP.
  47. Remove the oil pump.
    Fig 45: Removing Oil Pump
    G03312235Courtesy of MAZDA MOTORS CORP.
    48. NOTE:
    • Before removing the piston and connecting rod assemblies, inspect the top of the cylinder bores. If required, remove the cylinder ridge.
    Fig 46: Removing Piston & Connecting Rod Assemblies
    G03312236Courtesy of MAZDA MOTORS CORP.
  48. Remove the piston and connecting rod assemblies one at a time.
    1. Remove the connecting rod nuts in pairs.
    2. Remove the connecting rod cap.
    3. Remove the piston and connecting rod assembly.
  49. Remove the bolts and main bearing caps.
    Fig 47: Removing Main Bearing Caps
    G03312237Courtesy of MAZDA MOTORS CORP.
  50. Remove the lower crankshaft main bearings.
    Fig 48: Removing Lower Crankshaft Main Bearings
    G03312238Courtesy of MAZDA MOTORS CORP.
  51. Remove the crankshaft rear oil seal.
    Fig 49: Removing Crankshaft Rear Oil Seal
    G03312239Courtesy of MAZDA MOTORS CORP.
  52. Remove the crankshaft.
    Fig 50: Removing Crankshaft
    G03312240Courtesy of MAZDA MOTORS CORP.
  53. Remove the upper crankshaft main bearings.
    Fig 51: Removing Upper Crankshaft Main Bearings
    G03312241Courtesy of MAZDA MOTORS CORP.
scientia non olet · About LEMON Manuals