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Engine Front Cover Removal/Installation: Installation

WARNING: This page is about a different car, the 2002 Mazda B2300 and 2001 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: This step is needed only if a new front cover is being installed.
    Fig 1: Installing Fan Drive Pulley
    G01168010Courtesy of MAZDA MOTORS CORP.
  1. Install the fan drive pulley using a nut and bolt with flat washers.
  2. Clean and inspect the mounting surfaces of the engine and the front cover.
    3. NOTE: The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
    Fig 2: Applying Silicone Gasket & Sealant To Cylinder Head & Oil Pan Joint Areas
    G01168011Courtesy of MAZDA MOTORS CORP.
  3. Apply a 2.5 mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
  4. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:
    1. Tighten the 8 mm bolts to 10 N.m {1 kgf.m, 7 lbf}.
    2. Tighten the 10 mm bolts to 25 N.m {2.5 kgf.m, 18 lbf}.
    3. Tighten the 13 mm bolts to 48 N.m {4.889 kgf.m, 35 lbf}.
    Fig 3: Front Cover Bolt Tightening Sequence
    G01168012Courtesy of MAZDA MOTORS CORP.
  5. Position the power steering pump and install the lower retaining bolt.
    Fig 4: Installing Power Steering Pump Lower Retaining Bolt
    G01168013Courtesy of MAZDA MOTORS CORP.
  6. Connect the power steering return hose.
    Fig 5: Connecting Power Steering Return Hose
    G01168014Courtesy of MAZDA MOTORS CORP.
  7. Install a new nylon O-ring and install the high pressure line.
    Fig 6: Connecting Power Steering High Pressure Line
    G01168015Courtesy of MAZDA MOTORS CORP.
  8. Install the water pump pulley.
    Fig 7: Installing Water Pump Pulley
    G01168016Courtesy of MAZDA MOTORS CORP.
  9. Install the belt tensioner.
    Fig 8: Installing Belt Tensioner
    G01168017Courtesy of MAZDA MOTORS CORP.
    10. NOTE: Do not reuse the crankshaft damper bolt.
    Fig 9: Installing Crankshaft Pulley
    G01168018Courtesy of MAZDA MOTORS CORP.
  10. Install the crankshaft pulley and hand-tighten the bolt.
  11. Install an M6 bolt in the crankshaft pulley. Tighten the crankshaft retaining bolt in two stages.
    1. Stage 1: Tighten to 40 N.m {4.1 kgf.m, 30 lbf}.
    2. Stage 2: Rotate the bolt an additional 90 degrees.
    Fig 10: Installing Bolt In Crankshaft Pulley
    G01168019Courtesy of MAZDA MOTORS CORP.
  12. Install the crankshaft position sensor, do not tighten the bolts at this time.
    Fig 11: Installing Crankshaft Position Sensor
    G01168020Courtesy of MAZDA MOTORS CORP.
  13. Adjust the crankshaft position sensor with the Alignment Tool, and tighten the mounting bolts.
    Fig 12: Adjusting Crankshaft Position Sensor
    G01168021Courtesy of MAZDA MOTORS CORP.
  14. Connect the crankshaft position sensor electrical connector.
    Fig 13: Connecting Crankshaft Position Sensor Electrical Connector
    G01168022Courtesy of MAZDA MOTORS CORP.
  15. Remove the M6 bolt from the crankshaft pulley.
    Fig 14: Removing Bolt From Crankshaft Pulley
    G01168023Courtesy of MAZDA MOTORS CORP.
  16. Remove the Engine Timing Peg (ST 303-507)  .
    Fig 15: Removing Crankshaft Timing Peg
    G01168024Courtesy of MAZDA MOTORS CORP.
  17. Install the plug.
    Fig 16: Installing Plug
    G01168025Courtesy of MAZDA MOTORS CORP.
  18. Remove the Camshaft Alignment Plate (303-376)  .
    Fig 17: Removing Camshaft Alignment Plate
    G01168026Courtesy of MAZDA MOTORS CORP.
  19. Install the valve cover. See VALVE COVER REMOVAL/INSTALLATION 
  20. Install the drive belt. See DRIVE BELT REMOVAL/INSTALLATION .
  21. Install the fan and shroud. See ELECTRIC COOLING FAN REMOVAL/INSTALLATION .
  22. Connect the battery ground cable.
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