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Home › Mazda › 2003 › Tribute DX, 4WD › Repair and Diagnosis › Engine Mechanical › Engine Mechanical - 2.0L › Engine Reassembly › Assembly

Engine Reassembly: Assembly

WARNING: Eye protection is required to be worn during use of compressed air. Failure to follow these instructions could result in possible personal injury.
CAUTION: The engine sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; only use manual scrapers. Do not scratch or gouge sealing surfaces or oil leaks may occur.
  1. Carefully clean and dry the cylinder block.
    1. Clean gasket material, dirt and foreign material from the cylinder block.
    2. Wash the cylinder block with a suitable soap and water solution.
    3. Dry the cylinder block completely using compressed air.
  2. Install the Woodruff key.
    Fig 1: Installing Woodruff Key
    G02170845Courtesy of MAZDA MOTORS CORP.
  3. Install the upper crankshaft main bearings, the upper crankshaft thrust main bearing and the lower crankshaft main bearings.
    Fig 2: Installing Upper Crankshaft Main Bearings, Upper Crankshaft Thrust Main Bearing & Lower Crankshaft Main Bearings
    G02170846Courtesy of MAZDA MOTORS CORP.
    4. NOTE: Apply a light coat of SAE 5W-20 Motor Oil to the crankshaft bearings and journals.
    Fig 3: Positioning Crankshaft
    G02170847Courtesy of MAZDA MOTORS CORP.
  4. Position the crankshaft.
  5. Determine crankshaft main bearing clearance. Refer to CRANKSHAFT MAIN BEARING JOURNAL - CLEARANCE .
    6. CAUTION: Make sure the main bearing caps are installed in their original position or engine damage may occur
    NOTE: Apply a light coat of SAE 5W-20 Motor Oil to the crankshaft bearings and journals.
    Fig 4: Installing Main Bearing Caps
    G02170848Courtesy of MAZDA MOTORS CORP.
  6. Install the main bearing caps.
  7. Tighten the bolts using the sequence shown in two stages.
    1. Stage 1: Tighten the bolts to 25 Nm (18 lb-ft).
    2. Stage 2: Tighten the bolts an additional 60 degrees.
    Fig 5: Main Bearing Cap Bolt Tightening Sequence
    G02170849Courtesy of MAZDA MOTORS CORP.
  8. Rotate the crankshaft and inspect for excessive drag or binding.
    Fig 6: Rotating Crankshaft
    G02170850Courtesy of MAZDA MOTORS CORP.
  9. Inspect the crankshaft end play. Refer to CRANKSHAFT - END PLAY .
    10. CAUTION: PIP mark on pistons and squirt groove on connecting rods must be located on the intake side of the engine or possible engine damage may occur.
    CAUTION: Use care when installing piston and connecting rod assemblies. Do not scratch the cylinder walls or the crankshaft journals or engine damage may occur. Use care when installing piston and connecting rod assemblies. Do not scratch the cylinder walls or the crankshaft journals or engine damage may occur.
    CAUTION: The arrow on the piston must point toward the front of the engine or engine damage may occur.
    NOTE: Lubricate the cylinder block, piston rings and connecting rod prior to installation with SAE 5W-20 Motor Oil.
    Fig 7: Installing Piston & Connecting Rod Assemblies
    G02170851Courtesy of MAZDA MOTORS CORP.
    CAUTION: Connecting rods and connecting rod caps must be correctly oriented, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
    NOTE: Turn the crankshaft each time to install the connecting rod caps.
  10. Using the special tools, install the four piston and connecting rod assemblies.
  11. Fit the connecting rod bearing.
    1. Install the four upper and the four lower connecting rod bearings.
    2. Inspect the connecting rod bearing to the crankshaft clearance. Refer to CONNECTING ROD - BEARING JOURNAL CLEARANCE .
    Fig 8: Fitting Connecting Rod Bearing
    G02170852Courtesy of MAZDA MOTORS CORP.
    12. CAUTION: Connecting rods and connecting rod caps must be correctly oriented, the interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
    NOTE: Lubricate the connecting rod bearings and the crankshaft journals prior to installation with SAE 5W-20 Motor Oil.
    NOTE: Rotate the crankshaft after installing each connecting rod cap and inspect for excess drag or binding.
    Fig 9: Installing Connecting Rod Caps
    G02170853Courtesy of MAZDA MOTORS CORP.
  12. Install the connecting rod caps.
    1. Install new bolts and tighten in two stages:
    2. Stage 1: Tighten to 35 Nm (26 lb-ft).
    3. Stage 2: Tighten an additional 90 degrees.
    13. NOTE: The clearance between the lower cylinder block sealing surfaces on the crankshaft rear oil seal retainer and the crankshaft cannot exceed 0.5 mm (0.02 in).
    Fig 10: Installing Crankshaft Rear Oil Seal Retainer
    G02170854Courtesy of MAZDA MOTORS CORP.
  13. Install a new gasket, the crankshaft rear oil seal retainer and tighten the bolts in two stages:
    1. Stage 1: Tighten to 12 Nm (9 lb-ft).
    2. Stage 2: Tighten to an additional 45 degrees.
    14. NOTE: Lubricate the crankcase flange and the crankshaft rear oil seal bore with SAE 5W-20 Motor Oil prior to installing the crankshaft rear seal or damage to the crankshaft rear seal may occur.
    Fig 11: Installing Crankshaft Rear Seal
    G02170855Courtesy of MAZDA MOTORS CORP.
  14. Using the special tools, install a new crankshaft rear seal.
    15. NOTE: The clearance between the lower cylinder block sealing surfaces on the oil pump and the cylinder block cannot exceed 0.8 mm (0.031 in).
    Fig 12: Installing Oil Pump
    G02170856Courtesy of MAZDA MOTORS CORP.
  15. Install a new gasket, the oil pump and tighten the bolts in two stages:
    1. Stage 1: Tighten to 6 Nm (53 lb-in).
    2. Stage 2: Tighten an additional 45 degrees.
    16. NOTE: Lubricate the crankcase flange and the crankshaft front oil seal bore with SAE 5W-20 motor oil prior to installing the crankshaft front seal or damage to the crankshaft front seal may occur.
    Fig 13: Installing Crankshaft Front Seal
    G02170857Courtesy of MAZDA MOTORS CORP.
  16. Using the special tool, install a new crankshaft front seal.
    17. CAUTION: The lower engine block must be installed and the bolts tightened to specification within four minutes of sealant application or possible leakage may occur.
    NOTE: Apply a 3 mm (0.1 inch) bead of silicone gasket and sealant sealer in four places where the oil seal retainers meet the cylinder block.
    Fig 14: Installing Lower Cylinder Block
    G02170858Courtesy of MAZDA MOTORS CORP.
  17. Install a gasket and the lower cylinder block. Tighten the bolts using the sequence shown.
  18. Install the oil pump cover and screen.
    1. Install new oil pump inlet tube gasket.
    Fig 15: Installing Oil Pump Cover & Screen
    G02170859Courtesy of MAZDA MOTORS CORP.
    19. NOTE: The oil pan must be installed and the bolts tightened to specification within seven minutes of sealer application or oil leaks may occur.
    NOTE: Apply a 3 mm (0.1 inch) continuous bead of silicone gasket and sealant to the oil pan.
    Fig 16: Oil Pan Bolt Tightening Sequence
    G02170860Courtesy of MAZDA MOTORS CORP.
  19. Install the oil pan. Tighten the bolts in two stages using the sequence shown.
    1. Stage 1: Tighten to 6 Nm (53 lb-in).
    2. Stage 2: Tighten to 12 Nm (9 lb-ft).
    20. NOTE: Install a new pilot bearing on vehicles equipped with a manual transaxle only if it is damaged.
    Fig 17: Installing Pilot Bearing
    G02170861Courtesy of MAZDA MOTORS CORP.
  20. Using the special tools, install the pilot bearing.
  21. Install a new head gasket on the cylinder block.
    22. CAUTION: The bolts are torque-to-yield and new bolts must be installed or engine damage may occur.
    Fig 18: Cylinder Head Bolt Tightening Sequence
    G02170862Courtesy of MAZDA MOTORS CORP.
  22. Install the cylinder head and tighten the bolts in three stages using the sequence shown.
    1. Stage 1: Tighten the bolts to 20 Nm (15 lb-ft).
    2. Stage 2: Tighten the bolts to 40 Nm (30 lb-ft).
    3. Stage 3: Tighten the bolts an additional 90 degrees.
  23. Install the timing belt guide and crankshaft sprocket.
    Fig 19: Installing Timing Belt Guide & Crankshaft Sprocket
    G02170863Courtesy of MAZDA MOTORS CORP.
  24. Install the oil cooler.
    1. Install a new oil cooler gasket.
    Fig 20: Installing Oil Cooler
    G02170864Courtesy of MAZDA MOTORS CORP.
  25. Install the knock sensor.
    Fig 21: Installing Knock Sensor
    G02170865Courtesy of MAZDA MOTORS CORP.
  26. Install the block heater if equipped.
    Fig 22: Installing Block Heater
    G02170866Courtesy of MAZDA MOTORS CORP.
  27. Install the oil pressure sensor.
    Fig 23: Installing Oil Pressure Sensor
    G02170867Courtesy of MAZDA MOTORS CORP.
    28. NOTE: Illustration shown with throttle body and fuel supply manifold removed for clarity.
    NOTE: Install new intake manifold gaskets if damaged.
    Fig 24: Intake Manifold Bolt Tightening Sequence
    G02170868Courtesy of MAZDA MOTORS CORP.
  28. Install the intake manifold and tighten using the sequence shown.
  29. Install the positive crankcase ventilation (PCV) tube.
    Fig 25: Installing Positive Crankcase Ventilation Tube
    G02170869Courtesy of MAZDA MOTORS CORP.
  30. Install the thermostat housing.
    1. Install a new O-ring seal if damaged.
    Fig 26: Installing Thermostat Housing
    G02170870Courtesy of MAZDA MOTORS CORP.
    31. NOTE: The coil is removed from picture for clarity.
    Fig 27: Installing Coil & Coil Bracket Assembly
    G02170871Courtesy of MAZDA MOTORS CORP.
  31. Install the coil and coil bracket assembly.
  32. Install the exhaust gas recirculation (EGR) tube.
    Fig 28: Installing Exhaust Gas Recirculation Tube
    G02170872Courtesy of MAZDA MOTORS CORP.
  33. Connect the EGR tube fitting.
    Fig 29: Connecting EGR Tube Fitting
    G02170873Courtesy of MAZDA MOTORS CORP.
  34. Install the fuel charging wiring harness and connect the following electrical connectors:
    1. Cylinder temperature sensor
    2. Throttle position sensor
    3. Wiring harness to vehicle
    4. Idle air control valve
    5. Camshaft position sensor
    6. Fuel injectors
    Fig 30: Installing Fuel Charging Wiring Harness
    G02170874Courtesy of MAZDA MOTORS CORP.
  35. Install the generator bracket.
    Fig 31: Installing Generator Bracket
    G02170875Courtesy of MAZDA MOTORS CORP.
  36. Install the generator.
    Fig 32: Installing Generator
    G02170876Courtesy of MAZDA MOTORS CORP.
  37. Install the inner timing belt cover.
    Fig 33: Installing Inner Timing Belt Cover
    G02170877Courtesy of MAZDA MOTORS CORP.
  38. Loosely install the crankshaft pulley and rotate the crankshaft to just before top dead center (TDC) (No. 1 cylinder).
    Fig 34: Rotating Crankshaft To Just Before Top Dead Center
    G02170878Courtesy of MAZDA MOTORS CORP.
  39. Remove the stud.
    Fig 35: Removing Stud
    G02170879Courtesy of MAZDA MOTORS CORP.
  40. Install the special tool.
    Fig 36: Installing Special Tool
    G02170880Courtesy of MAZDA MOTORS CORP.
    41. NOTE: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.
    Fig 37: Crankshaft At Top Dead Center
    G02170881Courtesy of MAZDA MOTORS CORP.
  41. Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder).
    1. Remove the crankshaft pulley.
    42. CAUTION: If valve tappets are being reused the valve tappet must be installed in its original position or engine damage may occur.
    NOTE: Lubricate the valve tappets prior to installation with SAE 5W-20 motor oil.
    Fig 38: Installing Valve Tappets
    G02170882Courtesy of MAZDA MOTORS CORP.
  42. Install the valve tappets.
    43. NOTE: The front camshaft journal cap must be installed and the bolts tightened to specification within four minutes of sealer application or oil leaks may occur.
    Fig 39: Front Camshaft Journal Cap Sealing Surface With Silicone Gasket Maker
    G02170883Courtesy of MAZDA MOTORS CORP.
  43. Coat the sealing surface of the front camshaft journal cap with silicone gasket maker.
    44. NOTE: Lubricate the camshaft bearing surfaces with SAE 5W-20 Motor Oil.
    Fig 40: Installing Camshafts
    G02170884Courtesy of MAZDA MOTORS CORP.
  44. Install the camshafts.
    1. Position the camshafts and camshaft journal caps.
    2. Install the bolts and tighten the bolts in several two-turn passes using the sequence shown.
    45. NOTE: The exhaust camshaft oil seal is shown, the intake seal similar.
    Fig 41: Installing Camshaft Front Oil Seals
    G02170885Courtesy of MAZDA MOTORS CORP.
  45. Using the special tool, install new camshaft front oil seals.
  46. Install the camshaft sprockets and hand tighten the bolts.
    1. Rotate the camshafts one full turn and inspect them for binding.
    Fig 42: Installing Camshaft Sprockets
    G02170886Courtesy of MAZDA MOTORS CORP.
  47. Verify the valve clearance. Refer to VALVE - VALVE CLEARANCE, ADJUST .
    48. CAUTION: The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the sprocket bolts. Damage to camshaft may result.
    NOTE: Installation of the alignment tool into the exhaust camshaft may require the camshaft to be rotated slightly.
    Fig 43: Installing Special Tool Onto Back Of The Camshafts
    G02170887Courtesy of MAZDA MOTORS CORP.
  48. Install the special tool onto the back of the camshafts.
  49. Loosen the timing sprocket bolts and allow the camshaft sprockets to move freely.
    Fig 44: Loosening Timing Sprocket Bolts
    G02170888Courtesy of MAZDA MOTORS CORP.
  50. Install the timing belt idler pulley.
    Fig 45: Installing Timing Belt Idler Pulley
    G02170889Courtesy of MAZDA MOTORS CORP.
  51. Install the water pump adapter.
    1. Install a new gasket.
    Fig 46: Installing Water Pump Adapter
    G02170890Courtesy of MAZDA MOTORS CORP.
    52. NOTE: Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block.
    Fig 47: Verifying Crankshaft Is At TDC Position
    G02170891Courtesy of MAZDA MOTORS CORP.
  52. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment peg.
    1. Remove the crankshaft pulley.
  53. Install the timing belt tensioner and the timing belt.
    1. Hand tighten the bolt.
    Fig 48: Installing Timing Belt Tensioner & Timing Belt
    G02170892Courtesy of MAZDA MOTORS CORP.
  54. Confirm that the timing belt tensioner is installed correctly with the tab positioned in the slot in the inner timing cover.
    Fig 49: Installing Timing Belt Tensioner With Tab Positioned In Inner Timing Cover Slot
    G02170893Courtesy of MAZDA MOTORS CORP.
  55. Adjust the timing belt tensioner.
    1. Using a 6mm Allen wrench, rotate the adjuster counterclockwise and align the marks as shown.
    2. Tighten the tensioner pulley bolt.
    Fig 50: Adjusting Timing Belt Tensioner
    G02170894Courtesy of MAZDA MOTORS CORP.
    56. CAUTION: The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft may result.
    NOTE: Use SST 303-098 to keep each camshaft from rotating.
    Fig 51: Tightening Camshaft Timing Sprocket Bolts
    G02170895Courtesy of MAZDA MOTORS CORP.
  56. Tighten the camshaft timing sprocket bolts to specifications.
  57. Remove the special tool.
    Fig 52: Removing Special Tool
    G02170896Courtesy of MAZDA MOTORS CORP.
  58. Install the bolts and the valve cover. Refer to VALVE COVER .
    1. Install the valve cover gasket.
    Fig 53: Installing Valve Cover
    G02170897Courtesy of MAZDA MOTORS CORP.
  59. Connect the ignition wires to the correct spark plugs.
    Fig 54: Connecting Ignition Wires To Spark Plugs
    G02170898Courtesy of MAZDA MOTORS CORP.
  60. Install the timing belt upper cover.
    Fig 55: Installing Timing Belt Upper Cover
    G02170899Courtesy of MAZDA MOTORS CORP.
  61. Install the lower engine mount bracket.
    Fig 56: Installing Lower Engine Mount Bracket
    G02170900Courtesy of MAZDA MOTORS CORP.
  62. Install the lower timing belt cover.
    Fig 57: Installing Lower Timing Belt Cover
    G02170901Courtesy of MAZDA MOTORS CORP.
  63. Install the accessory drive belt idler pulley.
    Fig 58: Installing Accessory Drive Belt Idler Pulley
    G02170902Courtesy of MAZDA MOTORS CORP.
    64. NOTE: Apply silicone gasket and sealant sealer to the crankshaft pulley keyway prior to installing the crankshaft pulley.
    Fig 59: Installing Crankshaft Pulley
    G02170903Courtesy of MAZDA MOTORS CORP.
  64. Install the crankshaft pulley.
  65. Install the coolant tube.
    1. Install the bolt.
    2. Connect the hose.
    Fig 60: Installing Coolant Tube
    G02170904Courtesy of MAZDA MOTORS CORP.
  66. Install the crankcase vent oil separator.
    1. Install the bolts.
      • Install a new gasket.
    2. Connect the PCV valve.
    Fig 61: Installing Crankcase Vent Oil Separator
    G02170905Courtesy of MAZDA MOTORS CORP.
  67. Install the catalytic converter bracket.
    Fig 62: Installing Catalytic Converter Bracket
    G02170906Courtesy of MAZDA MOTORS CORP.
  68. Install the crankshaft position sensor and bushing.
    Fig 63: Installing Crankshaft Position Sensor & Bushing
    G02170907Courtesy of MAZDA MOTORS CORP.
  69. Install the stud.
    Fig 64: Installing Stud
    G02170908Courtesy of MAZDA MOTORS CORP.
  70. Install the coolant tube.
    1. Install the bolt and nut.
    2. Connect the hose.
    Fig 65: Installing Coolant Tube
    G02170909Courtesy of MAZDA MOTORS CORP.
    Fig 66: Installing A/C Compressor Bracket
    G02170910Courtesy of MAZDA MOTORS CORP.
  71. Install the A/C compressor bracket.
    Fig 67: Installing Power Steering Pump Bracket
    G02170911Courtesy of MAZDA MOTORS CORP.
  72. Install the power steering pump bracket.
    Fig 68: Exhaust Manifold Bolt Tightening Sequence
    G02170912Courtesy of MAZDA MOTORS CORP.
  73. Install the exhaust manifold and tighten using the sequence shown.
    1. Install a new gasket.
  74. Install the oil level indicator and tube.
    1. Install a new O-ring seal if damaged.
    Fig 69: Installing Oil Level Indicator & Tube
    G02170913Courtesy of MAZDA MOTORS CORP.
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