Repair of gasoline engines Mazda 3 (BK)
As a power plant in Mazda 3 cars, 4-cylinder engines are used, in which the cylinders are arranged in one row. From below, the engine is closed by a sump that forms a crankcase, which is also a reservoir for oil, which is necessary for lubrication, cooling and protection of engine parts from wear.
All three engines are 16-valve, with four valves per cylinder. The valves are actuated by two overhead camshafts via poppet followers.
This section describes inspection procedures and repair operations without removing the engine from the vehicle, then discusses in detail the removal and installation procedure, and also describes the repair of parts located in the block and cylinder head.
Checking the content of CO / CH in the exhaust gases
The purpose of this test is to confirm that the content of CO/CH in the exhaust gases of the engine complies with the legal requirements for the toxicity of the exhaust...
The purpose of this test is to confirm that the content of CO/CH in the exhaust gases of the engine complies with the legal requirements for the toxicity of the exhaust...
Compression measurement in engine cylinders
Note. Measurement of compression in the engine cylinders is recommended in the following cases: reduced engine power, increased consumption of engine oil, increased fuel...
Note. Measurement of compression in the engine cylinders is recommended in the following cases: reduced engine power, increased consumption of engine oil, increased fuel...
Checking the accessory drive belt
Pic. 2.74. Checking the drive belt tension Check the position of the indicator mark of the automatic drive belt tensioner (pic. 2.74). If the position of the mark is not...
Pic. 2.74. Checking the drive belt tension Check the position of the indicator mark of the automatic drive belt tensioner (pic. 2.74). If the position of the mark is not...
Drive Belt Replacement
Remove the right mudguard. Pic. 2.75. Loose drive belt tension Turn the center of the tensioner pulley clockwise to loosen the drive belt tension (pic. 2.75). Remove the...
Remove the right mudguard. Pic. 2.75. Loose drive belt tension Turn the center of the tensioner pulley clockwise to loosen the drive belt tension (pic. 2.75). Remove the...
Checking the automatic drive belt tensioner
Remove the drive belt. Pic. 2.76. Checking the automatic drive belt tensioner: 1 - automatic drive belt tensioner Check that the automatic drive belt tensioner moves...
Remove the drive belt. Pic. 2.76. Checking the automatic drive belt tensioner: 1 - automatic drive belt tensioner Check that the automatic drive belt tensioner moves...
Checking thermal gaps in the valve drive mechanism
Disconnect the negative battery cable. Remove the right wheel. Remove the right mudguard. Remove spark plugs. Disconnect the high voltage wire. Disconnect the oil...
Disconnect the negative battery cable. Remove the right wheel. Remove the right mudguard. Remove spark plugs. Disconnect the high voltage wire. Disconnect the oil...
Adjustment of thermal gaps in the valve drive mechanism
Disconnect the negative battery cable. Remove the right wheel. Remove the right mudguard. Remove spark plugs. Disconnect the high voltage wire. Disconnect the oil...
Disconnect the negative battery cable. Remove the right wheel. Remove the right mudguard. Remove spark plugs. Disconnect the high voltage wire. Disconnect the oil...
General information and safety precautions when removing the power unit
If it was decided to remove the engine, then before that, carry out preparatory measures. It is extremely important to determine the place where the work will be carried...
If it was decided to remove the engine, then before that, carry out preparatory measures. It is extremely important to determine the place where the work will be carried...
Sealant removal
Pic. 2.87. Removing old sealant After removing the mounting bolts and nuts, use a suitable tool to remove the sealant (pic. 2.87). Attention! Be careful not to damage...
Pic. 2.87. Removing old sealant After removing the mounting bolts and nuts, use a suitable tool to remove the sealant (pic. 2.87). Attention! Be careful not to damage...
Removal and installation of the power unit
Remove the battery. Remove the battery tray. Remove the radiator. Drain the oil. Remove the power steering oil pump with oil filter without disconnecting the hose and...
Remove the battery. Remove the battery tray. Remove the radiator. Drain the oil. Remove the power steering oil pump with oil filter without disconnecting the hose and...
Removing support No. 1
Pic. 2.90. Hanging the engine with a special tool Suspend the engine using the special tool (pic. 2.90). Remove pinch bolt A from the #1 engine mount bracket side. Pic....
Pic. 2.90. Hanging the engine with a special tool Suspend the engine using the special tool (pic. 2.90). Remove pinch bolt A from the #1 engine mount bracket side. Pic....
Removing the #4 engine mount bracket and #4 engine mount
Pic. 2.92. engine jack Secure the engine and transmission to the final drive using an engine jack and accessory (pic. 2.92). Pic. 2.89. Components for mounting the power...
Pic. 2.92. engine jack Secure the engine and transmission to the final drive using an engine jack and accessory (pic. 2.92). Pic. 2.89. Components for mounting the power...
Installing Engine Mount Bracket #3
Pic. 2.95. Threaded (welding) #3 engine mount bracket stud: 1 - hairpin Tighten threaded (welding) the stud of the engine mount bracket No. 3 with a tightening torque of...
Pic. 2.95. Threaded (welding) #3 engine mount bracket stud: 1 - hairpin Tighten threaded (welding) the stud of the engine mount bracket No. 3 with a tightening torque of...
Installing the #4 engine mount bracket and #4 engine mount
Pic. 2.97. The order of tightening the bolt and nut of the #4 engine mount bracket and #4 engine mount Tighten a bolt and a nut of fastening of an arm of a support of...
Pic. 2.97. The order of tightening the bolt and nut of the #4 engine mount bracket and #4 engine mount Tighten a bolt and a nut of fastening of an arm of a support of...
Installation of support No. 1
Tighten bolt A of the engine mount bracket with a tightening torque of 93.1–116.6 Nm. Tighten the bolt B of the engine support bracket with a tightening torque of...
Tighten bolt A of the engine mount bracket with a tightening torque of 93.1–116.6 Nm. Tighten the bolt B of the engine support bracket with a tightening torque of...
Checking the actuator for changing the valve timing (L3)
Attention! The actuator for changing the valve timing is a precision assembly and cannot be disassembled. Disconnect the negative battery cable. Remove the plug hole...
Attention! The actuator for changing the valve timing is a precision assembly and cannot be disassembled. Disconnect the negative battery cable. Remove the plug hole...
Removal and installation of the actuator for changing the valve timing (L3)
Note. The camshaft sprocket of the variable valve timing actuator is integrated with the mechanism itself, therefore it is removed together with the assembly. Remove the...
Note. The camshaft sprocket of the variable valve timing actuator is integrated with the mechanism itself, therefore it is removed together with the assembly. Remove the...
Timing Chain — Preliminary Operations
Disconnect the negative battery cable. Remove spark plugs. Remove the right wheel. Remove the right mudguard. Loosen the water pump pulley bolt and remove the drive...
Disconnect the negative battery cable. Remove spark plugs. Remove the right wheel. Remove the right mudguard. Loosen the water pump pulley bolt and remove the drive...
Removing the crankshaft pulley mounting bolt
Remove the lower plug of the block of cylinders. Pic. 2.103. Installing a special tool Install special tool (pic. 2.103). Turn the crankshaft clockwise to TDC on...
Remove the lower plug of the block of cylinders. Pic. 2.103. Installing a special tool Install special tool (pic. 2.103). Turn the crankshaft clockwise to TDC on...
Removing the chain tensioner
Pic. 2.105. Installing the special tool on the crankshaft: 1 - tensioner piston Using a thin screwdriver, pry the chain tensioner ratchet away from the ratchet shaft...
Pic. 2.105. Installing the special tool on the crankshaft: 1 - tensioner piston Using a thin screwdriver, pry the chain tensioner ratchet away from the ratchet shaft...
Removing the timing chain
Pic. 2.106. Fixing the oil pump sprocket: 1 - special device Fix the oil pump sprocket with the special tool (pic. 2.106). Then remove the sprocket and chain. Pic....
Pic. 2.106. Fixing the oil pump sprocket: 1 - special device Fix the oil pump sprocket with the special tool (pic. 2.106). Then remove the sprocket and chain. Pic....
Timing chain installation
Pic. 2.106. Fixing the oil pump sprocket: 1 - special device Install the oil pump sprocket and fix it with a special tool (see fig. 2.106). Pic. 2.86. Installing the...
Pic. 2.106. Fixing the oil pump sprocket: 1 - special device Install the oil pump sprocket and fix it with a special tool (see fig. 2.106). Pic. 2.86. Installing the...
Installing the engine front cover
Apply silicone sealant to the front cover of the engine, in the places shown in Figure 2.108. Pic. 2.108. Places for applying sealant to the front cover of the engine...
Apply silicone sealant to the front cover of the engine, in the places shown in Figure 2.108. Pic. 2.108. Places for applying sealant to the front cover of the engine...
Installation of a forward epiploon of a cranked shaft
Apply clean engine oil to the oil seal. Press the seal lightly by hand. Pic. 2.110. Pressing in the front seal: 1- special fixture Press in the oil seal using a special...
Apply clean engine oil to the oil seal. Press the seal lightly by hand. Pic. 2.110. Pressing in the front seal: 1- special fixture Press in the oil seal using a special...
Installing rubber engine mount #3 and engine mount #3
Pic. 2.95. Threaded (welding) #3 engine mount bracket stud: 1 - hairpin Tighten the threaded stud of the engine support bracket No. 3 with a tightening torque of 7–13 Nm...
Pic. 2.95. Threaded (welding) #3 engine mount bracket stud: 1 - hairpin Tighten the threaded stud of the engine support bracket No. 3 with a tightening torque of 7–13 Nm...
Installing the crankshaft pulley mounting bolt
Pic. 2.86. Installing the special tool on the camshaft Install the special tool on the camshaft (see fig. 2.86). Pic. 2.113. Crankshaft pulley lock bolt: 1 - bolt...
Pic. 2.86. Installing the special tool on the camshaft Install the special tool on the camshaft (see fig. 2.86). Pic. 2.113. Crankshaft pulley lock bolt: 1 - bolt...
Installing the cylinder head cover
Pic. 2.114. Sealing locations Apply silicone sealant to the mating surfaces of the cylinder block at the locations indicated by the arrows (pic. 2.114). Application...
Pic. 2.114. Sealing locations Apply silicone sealant to the mating surfaces of the cylinder block at the locations indicated by the arrows (pic. 2.114). Application...
Removal and installation of the control oil valve (OCV) (L3)
Disconnect the negative battery cable. Remove the plug hole plate. Remove the high voltage wire. Disconnect the oil control valve connector (OCV). Measure the resistance...
Disconnect the negative battery cable. Remove the plug hole plate. Remove the high voltage wire. Disconnect the oil control valve connector (OCV). Measure the resistance...
Check Oil Control Valve (OCV) (L3)
Disconnect the negative battery cable. Disconnect the oil control valve connector. Pic. 2.103. Installing a special tool Measure the resistance between terminals A and B...
Disconnect the negative battery cable. Disconnect the oil control valve connector. Pic. 2.103. Installing a special tool Measure the resistance between terminals A and B...
Spool Valve Operation Test (OCV) (L3)
Disconnect the negative battery cable. Remove the oil control valve. Pic. 2.118. Primary check of the spool valve position of the oil control valve: 1 - spool valve...
Disconnect the negative battery cable. Remove the oil control valve. Pic. 2.118. Primary check of the spool valve position of the oil control valve: 1 - spool valve...
Dismantling of a head of the block of cylinders
Pic. 2.120. Components of the first stage of disassembly of the cylinder head: 1 - fastening bolts of camshaft sprockets; 2 - camshaft sprockets; 3 - control oil valve...
Pic. 2.120. Components of the first stage of disassembly of the cylinder head: 1 - fastening bolts of camshaft sprockets; 2 - camshaft sprockets; 3 - control oil valve...
Dismantling of the block of cylinders
Remove the cylinder head. Remove the oil pan. Remove the oil filter. Remove the oil cooler. Remove the knock sensor. Remove the oil separator. Remove the thermostat....
Remove the cylinder head. Remove the oil pan. Remove the oil filter. Remove the oil cooler. Remove the knock sensor. Remove the oil separator. Remove the thermostat....
Checking the cylinder head
Pic. 2.136. The use of dye when checking the cylinder block Perform a color contrast check of the cylinder head surface. Using a penetrating dye, check for cracks in the...
Pic. 2.136. The use of dye when checking the cylinder block Perform a color contrast check of the cylinder head surface. Using a penetrating dye, check for cracks in the...
Checking the valve guide
Pic. 2.138. Valve head thickness measurement Measure the head thickness of each valve (pic. 2.138). If the thickness is not correct, replace the valve. Head Thickness:...
Pic. 2.138. Valve head thickness measurement Measure the head thickness of each valve (pic. 2.138). If the thickness is not correct, replace the valve. Head Thickness:...
Valve length measurement
Pic. 2.139. Valve length Measure the length of each valve (pic. 2.139). If the length is not correct, replace the valve. Standard length L: Intake: 102.99-103.79mm;...
Pic. 2.139. Valve length Measure the length of each valve (pic. 2.139). If the length is not correct, replace the valve. Standard length L: Intake: 102.99-103.79mm;...
Valve Stem Diameter Measurement
Pic. 2.140. Bar diameter measurement Measure the stem diameter of each valve in the X and Y directions at three points with a micrometer (A, B, and C) as shown in Figure...
Pic. 2.140. Bar diameter measurement Measure the stem diameter of each valve in the X and Y directions at three points with a micrometer (A, B, and C) as shown in Figure...
Measuring the inner diameter of the valve guide
Pic. 2.141. Measuring the inner diameter of the valve guide Measure the inside diameter of each valve guide in the X and Y directions at three points (A, B, and C), as...
Pic. 2.141. Measuring the inner diameter of the valve guide Measure the inside diameter of each valve guide in the X and Y directions at three points (A, B, and C), as...
Measuring valve guide protrusion
Pic. 2.143. Measured height: 1 - valve guide sleeve; 2 – a head of the block of cylinders Measure the height of the protrusion (size A) each valve guide, excluding lower...
Pic. 2.143. Measured height: 1 - valve guide sleeve; 2 – a head of the block of cylinders Measure the height of the protrusion (size A) each valve guide, excluding lower...
Valve Guide Replacement
Pic. 2.144. Removing the valve guide: 1 - valve guide Remove the valve guide from the combustion chamber side using the special tool (pic. 2.144). Pic. 2.145. Assembling...
Pic. 2.144. Removing the valve guide: 1 - valve guide Remove the valve guide from the combustion chamber side using the special tool (pic. 2.144). Pic. 2.145. Assembling...
Pressing in the valve guide
Pic. 2.146. Pressing in the valve guide: 1 - valve guide Press the valve guide from the side opposite the camshaft until the special tool stops against the cylinder head...
Pic. 2.146. Pressing in the valve guide: 1 - valve guide Press the valve guide from the side opposite the camshaft until the special tool stops against the cylinder head...
Valve seat inspection and repair
Pic. 2.147. Valve seat width measurement Measure the width of the valve seat contact surface. If necessary, rework the valve seat or valve disc using the appropriate...
Pic. 2.147. Valve seat width measurement Measure the width of the valve seat contact surface. If necessary, rework the valve seat or valve disc using the appropriate...
Checking the valve spring
Pic. 2.150. Valve Spring Height Check Apply a compressive force to the spring and check the height of the spring (pic. 2.150). If the height is not correct, replace the...
Pic. 2.150. Valve Spring Height Check Apply a compressive force to the spring and check the height of the spring (pic. 2.150). If the height is not correct, replace the...
Checking the camshaft
Install the #1 and #5 camshaft journals onto the wedges. Pic. 2.152. Measuring camshaft runout Measure camshaft runout (pic. 2.152). If the runout is not correct,...
Install the #1 and #5 camshaft journals onto the wedges. Pic. 2.152. Measuring camshaft runout Measure camshaft runout (pic. 2.152). If the runout is not correct,...
Measuring the diameter of the camshaft journal
Pic. 2.154. Measuring the diameter of the camshaft journal Measure the diameters of the shaft journal in the X and Y directions at two points (A and B), as shown in...
Pic. 2.154. Measuring the diameter of the camshaft journal Measure the diameters of the shaft journal in the X and Y directions at two points (A and B), as shown in...
Measuring the radial clearance of the camshaft journal
Remove the valve lifter. Pic. 2.155. Installation of calibrated plastic wire Place pieces of calibrated plastic wire on top of the camshaft journals, placing them along...
Remove the valve lifter. Pic. 2.155. Installation of calibrated plastic wire Place pieces of calibrated plastic wire on top of the camshaft journals, placing them along...
Measuring the axial clearance of the camshaft journal
Install the camshaft bearing cap. Pic. 2.156. Measuring the axial clearance of the camshaft Measure the camshaft end play (pic. 2.156). If the clearance is not correct,...
Install the camshaft bearing cap. Pic. 2.156. Measuring the axial clearance of the camshaft Measure the camshaft end play (pic. 2.156). If the clearance is not correct,...
Valve lifter check
Pic. 2.157. Measuring the inner diameter of the tappet bore Measure the inner diameter of the tappet bore in the X and Y directions at two points (A and B) (pic. 2.157)....
Pic. 2.157. Measuring the inner diameter of the tappet bore Measure the inner diameter of the tappet bore in the X and Y directions at two points (A and B) (pic. 2.157)....
Checking the block of cylinders
Pic. 2.159. Measurement of the degree of warping of the surface of the cylinder block Measure the degree of warping of the surface of the cylinder block in six...
Pic. 2.159. Measurement of the degree of warping of the surface of the cylinder block Measure the degree of warping of the surface of the cylinder block in six...
Checking the oil spray nozzle valve
Pic. 2.161. Oil Spray Nozzle Valve Test Diagram Apply compressed air to oil spray nozzle valve A and check that air flows through valve B (pic. 2.161). If air does not...
Pic. 2.161. Oil Spray Nozzle Valve Test Diagram Apply compressed air to oil spray nozzle valve A and check that air flows through valve B (pic. 2.161). If air does not...
Piston check
Attention! In normal practice, the piston, piston ring and connecting rod are not disassembled. When replacing a piston, the piston pin, piston ring and connecting rod...
Attention! In normal practice, the piston, piston ring and connecting rod are not disassembled. When replacing a piston, the piston pin, piston ring and connecting rod...
Checking the crankshaft
Install the main bearing cap. Measure the end clearance of the crankshaft. If the clearance is not correct, replace the thrust bearing or crankshaft so that the...
Install the main bearing cap. Measure the end clearance of the crankshaft. If the clearance is not correct, replace the thrust bearing or crankshaft so that the...
Measuring the amount of runout of the crankshaft
Remove the main bearing cap. Measure the amount of runout of the crankshaft. If the crankshaft runout exceeds the maximum, replace the crankshaft. Pic. 2.166. Measuring...
Remove the main bearing cap. Measure the amount of runout of the crankshaft. If the crankshaft runout exceeds the maximum, replace the crankshaft. Pic. 2.166. Measuring...
Measuring the diameters of the crankshaft journals
Pic. 2.167. Measuring the diameters of the crankshaft journals Measure the diameters of the shaft journal in the X and Y directions at two points (A and B), as shown in...
Pic. 2.167. Measuring the diameters of the crankshaft journals Measure the diameters of the shaft journal in the X and Y directions at two points (A and B), as shown in...
Measuring the radial clearance in the main bearings of the crankshaft
Install the main bearing cap and crankshaft. Place pieces of calibrated plastic wire on top of the shaft journals, arranging them along the axis. Install the main...
Install the main bearing cap and crankshaft. Place pieces of calibrated plastic wire on top of the shaft journals, arranging them along the axis. Install the main...
Checking the side clearance of the connecting rod
Install the connecting rod cap. Pic. 2.169. Connecting Rod Backlash Measurement Measure the backlash of the bottom end of the connecting rod (pic. 2.169). If the...
Install the connecting rod cap. Pic. 2.169. Connecting Rod Backlash Measurement Measure the backlash of the bottom end of the connecting rod (pic. 2.169). If the...
Connecting Rod Radial Clearance Measurement
Remove the connecting rod cover. Pic. 2.170. Place of installation of the calibrated plastic wire Place pieces of calibrated plastic wire on top of the camshaft...
Remove the connecting rod cover. Pic. 2.170. Place of installation of the calibrated plastic wire Place pieces of calibrated plastic wire on top of the camshaft...
Bolt check
Pic. 2.171. Measuring bolt length Measure the length of each bolt (pic. 2.171). Replace all bolts that are longer than the maximum. Length L
Pic. 2.171. Measuring bolt length Measure the length of each bolt (pic. 2.171). Replace all bolts that are longer than the maximum. Length L
Installing main bearing caps
Pic. 2.172. The order of tightening the bolts of the main bearing caps Establish covers of radical bearings and tighten bolts of fastening in the order specified in...
Pic. 2.172. The order of tightening the bolts of the main bearing caps Establish covers of radical bearings and tighten bolts of fastening in the order specified in...
Installation of piston rings
Pic. 2.173. Scheme of installation of the oil scraper ring Install the two segments of the oil scraper ring and expander (pic. 2.173). Make sure the second ring is...
Pic. 2.173. Scheme of installation of the oil scraper ring Install the two segments of the oil scraper ring and expander (pic. 2.173). Make sure the second ring is...
Piston Assembly
Pic. 2.174. The layout of the piston ring locks: 1 - upper ring; 2 - upper oil scraper ring; 3 - lower oil scraper ring; 4 - oil scraper ring expander and second ring...
Pic. 2.174. The layout of the piston ring locks: 1 - upper ring; 2 - upper oil scraper ring; 3 - lower oil scraper ring; 4 - oil scraper ring expander and second ring...
Connecting rod bearing and cap installation
Pic. 2.176. Connecting rod installation Install connecting rod bearings in the head and connecting rod cover, as shown in Figure 2.176. Attention! When assembling and...
Pic. 2.176. Connecting rod installation Install connecting rod bearings in the head and connecting rod cover, as shown in Figure 2.176. Attention! When assembling and...
Assembling the balancing block (L3 with variable valve timing)
Check that the balancing block gear is not damaged, also check that the shaft rotates smoothly. Attention! The balancing block cannot be dismantled, as it has a high...
Check that the balancing block gear is not damaged, also check that the shaft rotates smoothly. Attention! The balancing block cannot be dismantled, as it has a high...
Installation of drive plate (with automatic transmission), flywheel (with manual transmission)
Install and press in the crankshaft rear oil seal. Hold the crankshaft from turning with the special tool. Pic. 2.180. The order of tightening the bolts of the flywheel...
Install and press in the crankshaft rear oil seal. Hold the crankshaft from turning with the special tool. Pic. 2.180. The order of tightening the bolts of the flywheel...
Oil pan installation
Pic. 2.181. Places for applying sealant to the mating surface of the oil pan Apply a continuous strip of organosilicon sealant to the mating surface of the oil pan as...
Pic. 2.181. Places for applying sealant to the mating surface of the oil pan Apply a continuous strip of organosilicon sealant to the mating surface of the oil pan as...
Installing the oil seal
Establish the case of output branch pipes of system of cooling. Install the recirculation tube. Press the valve stem seal onto the valve guide by hand. Pic. 2.184....
Establish the case of output branch pipes of system of cooling. Install the recirculation tube. Press the valve stem seal onto the valve guide by hand. Pic. 2.184....
Installing the cylinder head
Install the cylinder head. Pic. 2.186. The order of tightening the cylinder head bolts Tighten bolts of fastening of a head of the block of cylinders in the order...
Install the cylinder head. Pic. 2.186. The order of tightening the cylinder head bolts Tighten bolts of fastening of a head of the block of cylinders in the order...
Installation of camshafts
Install the camshafts with the #1 cylinder piston at TDC on the compression stroke. Pic. 2.187. The order of tightening the bolts of the camshaft bearing caps Tighten...
Install the camshafts with the #1 cylinder piston at TDC on the compression stroke. Pic. 2.187. The order of tightening the bolts of the camshaft bearing caps Tighten...
Timing mechanism drive assembly
Install the crankshaft sprocket. Install the oil pump chain. Pic. 2.189. Fixing the oil pump chain with a special tool Fix the oil pump sprocket with the special tool...
Install the crankshaft sprocket. Install the oil pump chain. Pic. 2.189. Fixing the oil pump chain with a special tool Fix the oil pump sprocket with the special tool...
Removal and installation of the oil pump (diesel)
Pic. 2.297. Oil pump components: 1 – cover of the oil pump; 2 – inner rotor, outer rotor; 3 - plunger plug; 4 - plunger spring; 5 - control plunger; 6 - oil pump housing...
Pic. 2.297. Oil pump components: 1 – cover of the oil pump; 2 – inner rotor, outer rotor; 3 - plunger plug; 4 - plunger spring; 5 - control plunger; 6 - oil pump housing...
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