Repair of diesel engines Mazda 3 (BK)

Diesel Engine Components
Fig. 2.232. Z6 engine components: 1 – drive belt; 2 – automatic drive belt tensioner; 3 – valve tappet; 4 - timing mechanism drive chain; 5 – cylinder head gasket; 6 –...

Checking the accessory drive belt
Fig. 2.233. Checking the drive belt tension Check the position of the drive belt automatic tensioner indicator mark (fig. 2.233). If the position of the mark is not...

Replacing the drive belt
Remove the bottom cover and splash guard (right). Fig. 2.234. Loosening the drive belt tension Turn the automatic drive belt tensioner in the direction shown in Figure...

Checking the automatic drive belt tensioner
Remove the drive belt. Fig. 2.235. Checking the automatic drive belt tensioner: 1 – Automatic drive belt tensioner Check the smooth movement of the automatic drive belt...

Checking thermal clearances in the valve drive mechanism
Remove the battery cover. Disconnect the negative cable from the battery. Remove the bottom cover and splash guard (right). Remove the air filter assembly. Remove the...

Adjusting thermal clearances in the valve drive mechanism
Remove the battery cover. Disconnect the negative cable from the battery. Remove the front wheel and tire (right). Remove the air filter assembly. Remove the ignition...

Checking the compression in the cylinders
Warning: A hot engine can cause serious burns. Caution: Be careful not to get burned when removing and installing engine components. Make sure the battery is fully...

Components of the timing chain
Remove the battery cover. Disconnect the negative cable from the battery. Drain the coolant from the engine. Remove the following items: front wheel (right); bottom...

Removal the timing chain tensioner
Press the chain tensioner connector plate through the access hole on the left side using a thin flat-head screwdriver (precision screwdriver). Fig. 2.256. Chain...

Removal the timing chain
Fig. 2.258. Alignment of the crankshaft sprocket keyway with the timing mark Rotate the crankshaft clockwise and align the keyway of the crankshaft sprocket with the...

Installing the timing chain
Fig. 2.260. Alignment of the crankshaft sprocket keyway with the installation mark Align the crankshaft sprocket keyway with the timing mark, then set the piston of the...

Installing Engine Support #3
Fig. 2.266. Tightening the studs for fastening engine support No.3 Tighten the engine mount studs #3 (fig. 2.266). Tightening torque: 7–13 Nm. Install engine support #3...

Installing the crankshaft pulley mounting bolt support
Secure the crankshaft pulley using special tools. Tighten the crankshaft pulley mounting bolt. Tightening torque: 157–167 Nm.

Installing the cylinder head cover
Fig. 2.268. Scheme for applying silicone sealant Apply silicone sealant as shown in Figure 2.268. Thickness of the applied sealant bead: 2–6 mm. Length of the applied...

Final installation of the timing chain
Install the remaining components in the reverse order of removal. Start the engine. Check and adjust the following if necessary: engine oil level; pulley and belt;...

Replacing the cylinder block gasket
Fig. 2.270. Cylinder block gasket: 1 – camshaft bearing cap; 2 – camshaft; 3 – cylinder head; 4 – cylinder head gasket Removal Remove the timing chain. Remove the EGR...

Installing the camshaft bearing cap
Set the camshaft to TDC position of cylinder No.1, and install the camshaft. Fig. 2.275. Installation positions of camshaft bearing caps Install the camshaft bearing...

Replacing the front crankshaft oil seal
Fig. 2.277. Crankshaft pulley: 1 – crankshaft pulley mounting bolt; 2 – crankshaft pulley; 3 – front oil seal Removal Remove the battery cover. Disconnect the negative...

Replacing the rear crankshaft oil seal
Removal Remove from automatic transmission model: gearbox; leading disk. Remove from manual transmission model: clutch slave cylinder; manual transmission in block with...

Removal and installation the engine
Fig. 2.281. Powertrain components: 1 – Main fuse box connector; 2 – Engine support No.3; 3 – battery platform bracket; 4 – Engine support No.4; 5 – engine, gearbox in...

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Mazda3 BK (2003-2009)