Timing Component Alignment Marks: Service and Repair

Timing Component Alignment

CAUTION:The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise, severe damage could occur.

CAUTION:Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.






1.

CAUTION:The special tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
NOTE:The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.
Install the camshaft alignment plate (2.3L) SST in the slots on the rear of both camshafts.






2. Remove the plug bolt.






3.
NOTE:Only turn the engine in the normal direction of rotation.
NOTE:Installing the special tool in this step will prevent the engine from being rotated in the clockwise direction. However, the engine can still be rotated in the counterclockwise direction.
Install the crankshaft TDC timing peg (2.3L) SST.






4. Install a M6 X 1.0 X 2.25 bolt (Mazda part # 1F20-12-428) to verify ignition timing.





Installation Note

1.
NOTE:Do not reuse the crankshaft damper bolt or washer.
NOTE:Apply clean engine oil on seal area before installing.
Install the new crankshaft pulley and hand-tighten the bolt.






2.

CAUTION:Only hand-tighten the bolt or damage to the front cover can occur.
NOTE:This step will correctly align the crankshaft pulley to the crankshaft.
Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.

- Rotate the crankshaft pulley as necessary to align the bolt holes.






3.

CAUTION:Failure to hold the crankshaft pulley in place during bolt tightening can cause damage to the engine front cover.Using the holding fixture SST, hold the crankshaft pulley in place and tighten the crankshaft pulley bolt in two stages.

- Stage 1: Tighten to 100 N-m {10.2 kgf-m, 74 ft-lbf}.
- Stage 2: Tighten an additional 90 degrees.






4. Remove the holding fixture SST.






5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.






6. Remove the crankshaft TDC timing peg (2.3L) SST.






7. Remove the camshaft alignment plate SST.






8.
NOTE:Only turn the engine in the normal direction of rotation.Turn the engine two complete revolutions.

9.
NOTE:Only turn the engine in the normal direction of rotation.Turn the engine until the No. 1 piston is at TDC.

10. Install the crankshaft TDC timing peg (2.3L) SST.






11.

CAUTION:Only hand-tighten the bolt or damage to the front cover can occur.Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.

- If it is not possible to install the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, correct the engine timing.






12. Using the camshaft alignment plate SST, check the position of the camshafts.

- If it is not possible to install the camshaft alignment plate SST, correct the engine timing.






13. Remove the camshaft alignment plate SSTl.






14. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.






15. Remove the crankshaft TDC timing peg (2.3L) SST.






16. Install the plug bolt.