VARIABLE VALVE TIMING ACTUATO VARIABLE VALVE … › El_Jared › cf75ef6e-3e01...8/27/2015 DirectHit Search Fixes\Information Available Asset Details

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VARIABLE VALVE TIMING ACTUATO...

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2007 CX7 Engine

VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [L3 WITH TC]

CAUTION:

Remove the variable valve timing actuator and camshaft sprocket as a single unit.

NOTE:

The variable valve timing actuator and camshaft sprocket cannot be disassembled.

1. Disconnect the negative battery cable.

2. Remove the splash shield (RH).

3. Remove the charge air cooler. (See INTAKEAIR SYSTEM REMOVAL/INSTALLATION [L3 WITH TC].)

4. Remove the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [L3WITH TC].)

5. Remove the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].)

6. Disconnect the wiring harness.

7. Remove the ventilation hose.

8. Remove the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [L3 WITH TC].)

9. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].)

10. Remove the front drive belt idler pulley. (See TIMING CHAIN REMOVAL/INSTALLATION [L3 WITH TC].)

11. Remove the engine front cover lower blind plug.

12. Remove the engine front cover upper blind plug.



13. Remove the cylinder block lower blind plug, and install the SST.

14. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at TDC of thecompression stroke. (Until the counterweight contacts SSTand stops.)

15. Loosen the timing chain using the following procedure:

a. Insert a suitable bolt (M6 X 1.0, length 25—35 mm {0.99—1.3 in})into the engine frontcover upper service hole and tighten it until it contacts the chain tensioner arm, and then rotateit back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does notcontact it.)



b. Drain the engine oil in the chain tensioner.

NOTE:

The plunger of the chain tensioner will be pushed in by rotating the exhaustcamshaft. As a result, engine oil leakage will occur.

i. Set a wrench on the cast hexagon of the exhaust camshaft and one on the casthexagon of the intake camshaft.

ii. While holding the intake camshaft so that it does not rotate, move the wrench onthe exhaust camshaft side back and forth. (Repeat approx. 10 times)

c. Remove the wrench set to the intake camshaft.

d. Using the SST (48 G010 4A0), release the chain tensioner ratchet lock.

49 G010 4A0 component parts



i. Seat the nut to the cast hexagon stud and tighten by hand. At this time, leave thehandle lever removed.

ii. Set the stud in the engine front cover lower service hole. (Tighten by hand untilthe hexagon contacts the engine front cover)



iii. Rotate the stud counterclockwise and align it with the tensioner release arminsertion hole to the 2 o'clock position.

iv. Insert the tensioner release arm into the tensioner release arm insertion hole ofthe stud. (Insert until seated to the nut)

v. Assemble the handle lever to the stud.

vi. Assemble the 49 G010 403(Tensioner release guide) and flange bolt togetherand set it to the installation area of the idler pulley. (Tighten flange bolt by hand)



vii. Rotate counterclockwise slowly until the handle lever contacts the tensionerrelease guide. The ratchet lock will release by rotating to the position which contactsthe tensioner release guide.

NOTE:

If the tensioner release arm cannot be deformed and removed byhand, turn the nut and then remove it.

e. Verify that the ratchet lock is correctly released using the following procedure.

i. Hold the handle lever using the left hand.

ii. With the right hand, move the wrench set to the exhaust camshaft back and forth.At this time, if the handle lever does not thrust back in conjunction with themovement of the wrench, the ratchet lock is released.

If the handle lever thrusts back in line with the movement of thewrench, the ratchet lock is not released. If this occurs, release thelock using the following procedure.

NOTE:

Continue to perform the following procedure until the handle lever



does not thrust back. If it does not unlock, further rotate the handlelever as the chain tensioner position has deviated.

Lock is not released

While slowly rotating the handle lever counterclockwise, (whilepressing tensioner release guide ahead), move the wrench set to theexhaust camshaft back and forth.

f. While applying pressure to exhaust camshaft with the right hand in the clockwise direction,crimp the bolt set in the procedure (1) approx. 5 mm using the left hand. Fix the tensionerarm.

16. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.

CAUTION:

Perform the work carefully so that the washer does not drop out.

17. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.



18. Remove the oil control valve (OCV). (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION[L3WITH TC].)

19. Loosen the camshaft cap bolts in two or three passes in the order shown in the figure and remove thecamshaft cap.

NOTE:

The camshaft caps are to be kept ordered for correct reassembly in their originalpositions. Do not mix the caps.

20. Remove the variable valve timing actuator and the camshaft on the intake air side as a single unit.

21. Remove the variable valve timing actuator.

a. Place alignment marks on the camshaft and variable valve timing actuator as shown in thefigure so that the variable valve timing actuator is reassembled in its original position.

b. Fix the camshaft in a vise.



c. Loosen the variable valve timing actuator installation bolt.

22. Install a new washer.

23. Install the variable valve timing actuator.

NOTE:

When newly replacing the variable valve timing actuator, place alignment marks on thenew part in the same position as the old actuator.

If the alignment marks on the variable valve timing actuator are not available, refer to the“TIMING CHAIN ASSEMBLY” in the engine workshop manual and perform the sprocketposition alignment again.

a. Fix the camshaft in a vise.

b. Align the marks on the camshaft and the variable valve timing actuator.

c. Tighten the variable valve timing actuator installation bolt.

Tightening torque

69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}

24. Verify that the No.1 cylinder is at TDC of the compression stroke. (The position counterweightcontacts the SST.)

25. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in thefigure.


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26. With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timingactuator and the camshaft on the intake air side as a single unit.

27. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.However, do not apply it to the end journal of the intake camshaft.



28. Carefully apply adhesive agent (Loctite 518 or 962) to the area indicated in the figure so that it doesnot leak into the sliding part then, apply the gear oil (SAE No. 90 or equivalent) to the journal.

Adhesive agent thickness

1.0 mm {0.039 in}

29. Install the camshaft caps and temporarily tighten the camshaft cap bolts evenly in two or threepasses, and then tighten the camshaft cap bolts in two passes, using the following two steps and in theorder shown in the figure.



Tightening procedure

5.0—9.0 N·m {51—91 kgf·cm, 45—79 in·lbf}

14.0—17.0 N·m {1.5—1.7 kgf·m, 10.4—12.5 ft·lbf}

30. Install the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION[L3 WITH TC].)

31. Install the timing chain, exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a newwasher as a single unit.

CAUTION:

Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt beingcareful not to drop the washer.

Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing beforeperforming the bolt tightening.

32. Install the SSTon the camshaft as shown in the figure.

33. Remove the installation bolt for the engine front cover upper service hole ( M6 X 1.0 length 25—35mm {0.99—1.3 in}), and apply tension to the timing chain.

34. Rotate the crankshaft clockwise and verify that the No.1 cylinder is at TDC of the compression stroke.(The position counterweight contacts the SST.)



35. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.

Tightening torque

69—75 N·m {7.1—7.6 kgf·m, 51—55 ft·lbf}

36. Remove the SSTfrom the camshaft.

37. Remove the SSTinstalled in the cylinder block lower blind plug hole.

38. Rotate the crankshaft clockwise two turns and inspect the valve timing.

If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 32.

39. Apply the silicone sealant and install the engine front cover upper blind plug.

Tightening torque

8.0—11.5 N·m {82—117 kgf·cm, 71—101 in·lbf}

40. Install the cylinder block lower blind plug.



Tightening torque

18—22 N·m {1.9—2.2 kgf·m, 14—16 ft·lbf}

41. Install a new engine front cover lower blind plug.

Tightening torque

10.0—14.0 N·m {102—142 kgf·cm, 89—123 in·lbf}

42. Install the front drive belt idler pulley. (See TIMING CHAIN REMOVAL/INSTALLATION [L3 WITH TC].)

43. Install the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION[L3 WITH TC].)

44. Install the cylinder head cover. (See TIMING CHAIN REMOVAL/INSTALLATION [L3 WITH TC].)

45. Install the ventilation hose.

46. Connect the wiring harness.

47. Install the ignition coils. (See IGNITION COIL REMOVAL/INSTALLATION[L3 WITH TC].)



48. Install the high pressure fuel pump. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [L3WITH TC].)

49. Install the charge air cooler. (See INTAKEAIR SYSTEM REMOVAL/INSTALLATION [L3 WITH TC].)

50. Install the splash shield (RH).

51. Connect the negative battery cable.

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© 2012 Mazda North American Operations, U.S.A.

Portions of materials contained herein are sourced from Mazda Motor Corporation.

Copyright 2013 Service Repair Solutions, Inc.

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VARIABLE VALVE TIMING ACTUATO VARIABLE VALVE … › El_Jared › cf75ef6e-3e01...8/27/2015 DirectHit Search Fixes\Information Available Asset Details