Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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APPLICABLE MODEL(S) / VINS 2001-2007 Truck / B-Series (2.3L Only) 2005-2006 Tribute (2.3L Only) 2003-2007 Mazda6 (2.3L Only) 2004-2007 Mazda3 (2.0L & 2.3L) 2006-2007 Mazda5 2006-2007 Mazda MX-5 2006-2007 Mazdaspeed6 2007 Mazda CX-7 2007 Mazdaspeed3 DESCRIPTION When removing or replacing the crankshaft pulley on a 2.0L (Mazda3 only) or a 2.3L engine, be sure to follow the Workshop Manual procedures. The crankshaft pulley is not keyed to the crankshaft, and when loosened, it may move out of position on the crankshaft. The engine MUST be re-timed whenever the crankshaft pulley bolt is loosened, removed, or replaced. For normal aspirated engines, follow the Workshop Manual procedures and time the engine using Special Tools (Crankshaft Alignment Pin 303-507, Camshaft Alignment Timing Tool 303-465 and a standard M6 X 1.0 X 2.25 bolt). For direct injection spark ignition engines, follow the Workshop Manual procedures and time the engine using Special Tools (Crankshaft Alignment Pin 303-507, Camshaft Alignment Timing Tool 303-1061 and a standard M6 X 1.0 X 2.25 bolt). Please refer to the Mazda Job Aid on MS3 under Training titled “Engine Timing Verification and Correction LF2.0L and L3/L3T 2.3L” for more information. CAUTION: Engine damage will occur if the engine is not re-timed properly. Refer to applicable Workshop Manual (Section 01-10 – MECHANICAL – 2.0L (Mazda3 only) or 2.3L). NOTE: Damage to an engine caused by not following proper Workshop Manual procedures may result in denial of warranty claims or back charges.

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Common causes of camshaft timing belt failure on the above vehicles are due to incorrect operating tension, or ingress of dirt, water, or debris entering the timing belt cover. Predominantly on Fiesta models a high percentage of camshaft timing belt failures occur after the ancillary poly ‘V’ drive belt has failed, where strands of material off the broken belt have entered the timing belt cover. This is especially so where an ancillary belt has been fitted that does not contain “Kevlar” based materials. It is therefore important to always remove the timing belt cover to check for belt debris if the ancillary belt has failed. Any contamination that enters the timing belt cover can become compressed between the surfaces of the camshaft timing belt and drive pulleys. This causes wear to both the belt teeth, backing surface, and damage to the drive pulleys, resulting in premature failure of the camshaft timing belt. Later engines have modifications to improve the sealing of the belt cover around the crankshaft pulley, to reduce the level of outside contamination. Incorrect tensioning of the belt during installation will adversely affect the life of the belt. Before fitting a new belt it is important to check and observe the following points :- 1) Right Hand Inner Wing Splash Shield (Fiesta, Escort, Mondeo) This must be fitted and undamaged. 2) Timing Belt Cover Check that all components of the cover are fitted and undamaged. Ensure the latest type of modified cover is fitted. 3) a) Toothed Drive Pulleys Check that the tooth profiles are not worn or damaged. On vehicles built before January 1994 special attention should be given to the nylon toothed pulley situated below the camshaft pulley in a clockwise position on the belt drive (see diag item 4). This should be changed to a modified steel pulley (Ford No. 7053802) plus bolt (6701537). Ensure that the Camshaft and Injection Pump sprockets are free to rotate on the drive locations when the retaining bolts are slackened off. b) 4) a) b) c) Water Pump, Idler and Tensioner Pulleys Check that the belt running surfaces are not worn or damaged. Check that the flanges are running true and not damaged. Check that the water pump, and pulley bearings are in good condition, to ensure correct belt alignment. 5) Crankshaft Pulley The toothed pulley is in two parts. The rear section (Injection Pump Drive) is located onto the crankshaft by a small drive pin. The front section (Camshaft and “Poly V” belt drive) engages onto the rear pulley via a small vee protrusion on the rear face. Should the central fixing bolt for the crankshaft pulley come loose, or an old bolt re-used (Stretch bolt design), it is possible for fretting to take place damaging the locations. The crankshaft and camshaft pulleys can then move out of timing alignment, resulting in valve and piston contact damage. Replacement Procedure As the vehicle is fitted with two timing belts, one to drive the Camshaft, and one to drive the Injection Pump drives, which are driven off the crankshaft pulley, it is strongly recommended that both belts are replaced at the same time. NOTE: Special tools are required to lock the crankshaft, camshaft, and injection pump in the correct angular location when changing the belts, to ensure correct timing position. IMPORTANT: Ensure the engine is cold (not run for 4 hours) before commencing working as this will affect the setting of the timing belt tension and could lead to premature failure. Continued . . . .

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All vehicles 1. Remove the transmission. For additional information, refer to Section 307-01 for automatic transmissions or Section 308-03 for manual transmissions. Vehicles with manual transmission 2. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. All vehicles IN-VEHICLE REPAIR (Continued) 3. Remove the 10 bolts and flexplate or flywheel. • Discard the bolts. 4. NOTICE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin. Remove the flywheel front adapter. 5. NOTICE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear. NOTICE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep. NOTE: On original service seals, if equipped, the wear ring will be removed separately. Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.375 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the Slide Hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.344 in) to capture the metal case of the crankshaft rear seal as well as the wear ring. 6. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal. • Discard the crankshaft rear seal. Vehicles with an original service seal 7. NOTE: Original equipment seals will not have a wear ring. If a service part has previously been installed, it will have a wear ring. If the service part was a redesigned seal, the wear ring will have been removed with the seal in the previous step. If the service part was an original service seal, the wear ring will remain in the engine after the seal has been removed. If the wear ring remained in the engine after removing the seal, use the Crankshaft Rear Wear Ring Remover to remove and discard the crankshaft rear seal wear ring. All vehicles 8. Clean and inspect the crankshaft sealing surface. Installation Vehicles with an original service seal 1. NOTICE: The crankshaft rear seal and wear ring are a one-piece design and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur. NOTE: An original service seal will have a wear ring without a flange and pre-applied threadlock. NOTE: Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.

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Engine Front Cover If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection Procedure as outlined in Section 03-00. SPECIAL SERVICE TOOL(S) REQUIRED Description Crankshaft Damper Remover Vibration Damper and Seal Replacer T82L-6316-A Vibration Damper Remover Adapter Removal 1. Remove engine (6007) from vehicle. Refer to procedure in this section. 2. Loosen drive belt tensioner (6B209) and drive belt (8620) . 3. Remove water pump pulley retaining bolts and water pump pulley (8509) . 4. Remove retaining bolts and disconnect heater water outlet tube (18663) from water pump (8501) . 5. Disconnect electrical connector at camshaft position sensor. 6. Disconnect electrical connector at crankshaft position sensor (CKP sensor) (6C315) . 7. Remove retaining bolt and disconnect radiator lower hose tube (8291) from water pump . NOTE: If the vibration damper and crankshaft pulley have to be separated, mark the vibration damper and crankshaft pulley so that they may be reassembled in the same relative position. This is important as the vibration damper and crankshaft pulley are initially balanced as a unit. NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (6A328 or equivalent) must be installed on the new vibration damper in the same position as the original vibration damper. The crankshaft pulley (new or original) must also be installed in the same relative position as originally installed. 8. Remove crankshaft pulley (6312) and vibration damper assembly using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B. 9. Remove four retaining bolts and remove brace from A/C bracket and P/S bracket. 10. Remove oil bypass filter (6714) . Tool Number T58P-6316-D T82L-6316-B CAUTION: The engine front cover cannot be removed without lowering the oil pan (6675) . 11. Remove oil pan . Refer to procedure in this section. CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body (6603) . The engine front cover will break if pried upon and all retaining bolts are not removed. 12. Remove engine front cover retaining bolts. It is not necessary to remove water pump . 13. Remove engine front cover and water pump as an assembly. 14. Remove engine front cover gasket and discard. Water Pump Tightening Sequence Installation NOTE: Lightly oil all bolt and stud bolt threads before installation except those specifying special sealant. 1. Clean gasket surfaces on the engine front cover and cylinder block (6010) . If reusing the engine front cover , replace crankshaft front seal (6700) . Refer to Crankshaft Pulley and/or Damper and/or Crankshaft Front Seal in this section. 2. If a new engine front cover is to be installed: Install oil pump and filter body . Clean water pump gasket surface. Position a new water pump housing gasket (8507) on the engine front cover and install water pump . Install water pump retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). 3. Lubricate crankshaft front seal with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A is recommended to hold the engine front cover gasket (6020) in position while the engine front cover is installed. 4. Position a new engine front cover gasket on the cylinder block and install the engine front cover / water pump assembly using dowels for proper alignment. 5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft). Install the capscrew (Part No. N804841) nearest the oil bypass filter flange last, and tighten last. Apply Loctite® or equivalent to bolt prior to installation. Refer to illustration under Step 13 of removal procedure. 6. Install oil pan as outlined. 7. Install oil bypass filter . 8. Coat pulley sealing surface with clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E. NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to setup, and its sealing effectiveness may be reduced. 9. Apply a small amount of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to crankshaft keyway. 10. Position crankshaft key (6B316) in the crankshaft keyway.

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Special Precautions Special Precautions Disconnect battery earth lead. DO NOT turn crankshaft or camshaft when timing belt removed. Remove glow plugs to ease turning engine. Turn engine in normal direction of rotation (unless otherwise stated). DO NOT turn engine via camshaft or other sprockets. Observe all tightening torques. Check diesel injection pump timing after belt replacement. Removal Removal 1. Support engine. 2. Remove: Air filter and air intake hoses. Auxiliary drive belts. RH engine mounting. Vacuum pipe bracket. Timing belt upper cover [1]. 3. Turn crankshaft clockwise to TDC on No.1 cylinder. Ensure crankshaft sprocket timing marks aligned [2]. 4. Insert M6 x 1,00 bolt in camshaft sprocket and M8 x 1,25 bolt in injection pump sprocket to lock sprockets in position [3]. NOTE: If locating holes not aligned: Turn crankshaft one turn. 5. Remove: Crankshaft pulley (4 bolts). Timing belt lower cover [4]. 6. Slacken tensioner bolts [6]. Remove tensioner spring [5]. 7. Move tensioner pulley away from belt. Lightly tighten bolts. 8. Remove timing belt. Installation Installation 1. 2. 3. 4. 5. Use crankshaft pulley to check TDC marks aligned [2]. Ensure locking bolts located correctly [3]. Fit timing belt in clockwise direction, starting at crankshaft sprocket. Ensure belt is taut between sprockets. Temporarily fit crankshaft pulley. Ensure timing marks aligned [2]. Fit tensioner spring [5]. Corsa-B/Corsavan/Combo: Slacken tensioner bolts [6]. Allow tensioner to operate. Remove locking bolts [3]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns clockwise. Ensure timing marks aligned [2]. 6. Astra-F/Vectra/Cavalier: Slacken tensioner bolts [6]. Temporarily fit crankshaft pulley. Remove locking bolts [3]. Turn crankshaft 60° anti-clockwise (against normal direction of rotation) [7]. Tighten tensioner bolts to 19 Nm [6]. Turn crankshaft slowly two turns + 60° clockwise until timing marks aligned [2]. 7. 8. 9. 10. 11. Ensure timing marks aligned [2]. Ensure locking bolts can be inserted in sprockets [3]. If not: Repeat tensioning procedure. Remove crankshaft pulley. Fit timing belt lower cover [4]. Fit crankshaft pulley. Tighten bolts to 20 Nm. Install components in reverse order of removal.