ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... TIMING CHAIN REMOVAL/INSTALLATION [AJ] 1 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... Warning: Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injures or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". 1. Disconnect the negative battery cable. 2. Remove the dynamic chamber. 3. Remove the ignition coils. 4. Remove the front drive belt. 5. Remove the P/S oil pump and bracket with the P/S pipe connected, and fix the P/S oil pump using a rope to prevent it from falling. 6. Remove the A/C compressor with the A/C pipe connected, and fix the A/C compressor using a rope to prevent it from falling. 7. Disconnect the generator, but do not remove it from the vehicle. After disconnection, fix the generator using a rope to prevent it from falling. 8. Remove the drive shaft (RH). 9. Remove the front crossmember. 10. Remove the TWC (LH). 11. Remove the, oil pan. 12. Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Start the engine and: Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage. Verify the ignition timing, idle speed and idle mixture. 15. Perform a road test. Water Pump Drive Belt Pulley Removal Note 2 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... 1. Replace part A of the SST [303-009 (49 UN30 3009)] with the SST [303-457 (49 UN30 3457)]. 2. Remove the water pump pulley using the SSTs. Camshaft Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver as shown. Cylinder Head Cover (LH) Removal Note 3 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... 1. Remove the cylinder head cover bolts in the order shown. Engine Hanger Removal Note 1. Lift up the vehicle and loosen the engine hanger installation bolts from under the vehicle. Cylinder Head Cover (RH) Removal Note 1. Remove the cylinder head cover bolts in the order shown. 2. Remove the oil control valve (OCV) with cylinder head cover raised as shown in the figure. Note: 4 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... Take care not to let the OCV tightening bolt slip into the timing chain cover when removing the OCV tightening bolt from engine front. 3. Remove the cylinder head cover, No.3 Engine Joint Bracket Removal Note 1. Remove the ABS/TCS HU/CM connector. 2. Remove the dynamic chamber. 3. Using the bolts M12x1.25, length 25 mm (0.984 inch) to Install the SST as shown (LH bank and RH bank). Tightening torque 100 - 125 Nm (10.2 - 12.7 kgf-m, 73.8 - 92.1 ft. lbs.) 5 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... 4. Install the SST using the following procedure. Caution: Refer to the SST instruction manual for the basic handing procedure. 1) Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure. 2) Install the left rear shaft of the SST to the bolt of the left shock absorber. (identical position to the right side) Note: When setting the SST on the right side, make sure it doesn't interfere with the ABS (ABS/TCS) HU/CM or the DSC HU/CM. 6 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... 3) Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure. If equipped 4) Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal. 5) Make sure each joint is securely tightened. 5. Support the engine using the SST. Note: The SST (49 E01 7 5AO) can be used in place of the SST (49 CO 17 5AO). 6. Remove the No.3 engine joint bracket. Crankshaft Pulley Lock Bolt Removal Note 7 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... 1. Remove the A/C compressor with the pipes still connected. 2. Hold the crankshaft pulley using the SSTs. Crankshaft Pulley Removal Note 1. Remove the crankshaft pulley using the SST. Front Oil Seal Removal Note 1. Remove the front oil seal using a screwdriver as shown. 8 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... Engine Front Cover Removal Note 1. Remove the engine front cover bolts and studs in the order shown. Timing Chain Component (RH) Removal Note 1. Rotate the crankshaft clockwise so that the crankshaft keyway is in the 3 o'clock position. (The camshafts (RH) are in the neutral position.) Caution: Do not rotate the crankshaft counterclockwise. The timing chains may bind, causing engine damage. 9 of 27 1/15/2012 10:32 AM ALLDATA Online - 2004 Mazda 6 V6-3.0L DOHC - Service and Repair http://www.alldatapro.com/alldata/PRO~V237894171~C41009~R0~OD... 2. Place alignment marks on the timing chain corresponding to each of the alignment marks on the timing sprocket. 3. Remove the timing chain (RH) in the following order. 1) Chain tensioner 2) Tensioner arm 3) Timing chain 4) Chain guide 5) Timing chain crankshaft sprocket Camshaft Caps (RH) Removal Note 10 of 27 1/15/2012 10:32 AM