How to set timing on mazda 2.3 disi DOHC engine

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You need to take off the timing belt (or chain) cover and see why the one camshaft is not turning. Maybe the belt for that cam broke or the cam has seized from a bad cam bearing. One camshaft should be for the intake valves, the other cam is for the exhaust valves.

Did you take pictures while removing the originals? It's always a good habit. Below are the instructions you need to follow. Your own pics are very helpful when doing a big job like this.

1. Disconnect negative battery (1) cable.
2. Drain cooling system.
3. Remove upper intake manifold.
4. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.

CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

1. Align crankshaft sprocket timing mark to mark on oil pump housing (2). The mark on oil pump housing is 600 ATDC of #1 cylinder.

CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

1. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head.

1. Disconnect and remove camshaft position sensor (4) from left cylinder head.
2. Remove timing chain guide access plugs (3) from cylinder heads.

NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.

1. Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper (1) (if equipped) and sprocket.
2. Remove left side camshaft sprocket attaching bolts and remove sprocket.
3. Remove lower chain guide (7) and tensioner arm (8).
4. Remove the primary timing chain (5).
5. Remove crankshaft sprocket (6).

INSTALLATION

1. Inspect all sprockets (4,9,11) and chain guides (2,5,10). Replace if worn.
2. For crankshaft sprocket installation procedures Refer to CRANKSHAFT SPROCKET.
3. If removed, install right and left side short chain guides (11). Tighten attaching bolts to 28 Nm (250 inch lbs.) .
4. Align crankshaft sprocket timing mark to the mark on oil pump housing (3).

NOTE: Lubricate timing chain and guides with engine oil before installation.

1. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (1).

1. Lower the primary chain with left side sprocket through the left cylinder head opening.

NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.

1. Loosely position left side camshaft sprocket over camshaft hub.
2. Align timing (plated) link to the crankshaft sprocket timing mark (3).
3. Position primary chain onto water pump drive sprocket (10).
4. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely position over camshaft hub.
5. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
6. Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 28 Nm (250 inch lbs.) .

NOTE: Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

1. Install chain guide access plugs to cylinder heads. Tighten plugs to 20 Nm (15 ft. lbs.) .

NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

1. Purge oil from timing chain tensioner using the following procedure:

1. Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
2. Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

1. Reset timing chain tensioner using the following procedure:

1. Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
2. Apply a downward force until tensioner is reset.

NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball.

CAUTION: Ensure the tensioner is properly reset. The tensioner body (4) must bottom against the top edge of Special Tool 8186 (3). Failure to properly perform the resetting procedure may cause tensioner jamming.

NOTE: Inspect the tensioner O-ring (2) for nicks or cuts and make sure the snap ring (1) is correctly installed, replace as necessary.

1. Install the reset chain tensioner (1) into the right cylinder head.
2. Position tensioner retaining plate (2) and tighten bolts (1) to 12 Nm (105 inch lbs.) .

1. Starting at the right cylinder bank, first position the camshaft damper (1) (if equipped) on camshaft hub, then insert a 3/8 square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 inch lbs.) .
2. Turn the left side camshaft by inserting a 3/8 square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 inch lbs.).
3. Rotate engine slightly clockwise to remove timing chain slack, if necessary.

1. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then release the tensioner arm. Verify the tensioner is activated (extends).

1. Install camshaft position sensor (2) and connect electrical connector.
2. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
3. Install upper intake manifold.

NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds.

1. Fill cooling system.

Here you go This will help you

Engine - Timing Chain/Front Cover Revised Procedure
Classification:
EM98-009
Reference:
NTB98-107
Date:
January 15, 1999
GA16DE TIMING CHAIN/FRONT COVER
REVISED SERVICE PROCEDURE
APPLIED ENGINE:
GA16DE
APPLIED MODELS:
1991-94 Sentra (B13) w/GA16DE
1991-93 NX1600 (B13)
1995-99 Sentra (B14) w/GA16DE
1995-98 200SX (B14) w/GA16DE
SERVICE INFORMATION
A revised service procedure for the engine front cover/timing chain has been adopted for the GA16DE. It is no longer recommended to remove the
cylinder head when removing the timing chain/front cover(s). Utilize the following steps when servicing the front cover, timing chain, guides or
tensioner(s)
PARTS INFORMATION
CLAIMS INFORMATION
Please reference the "Revision C" pages of the Nissan "1992-1999 Warranty Flat Rate Information Manual", Section "AG", Op Codes AG12AA,
AG14AA, AG142A, AG143A, AG144A and AG24AA. Also reference Section "CA", Op Codes CA20AA and CA22AA. You will note that the
descriptions and flat rate times applicable to the B13 and B14 vehicles (with GA16DE engines) for these Op Codes have been revised to reflect this
new procedure.
Caution
^ After removing the timing chain, do not turn the crankshaft and camshaft separately or the valves will strike the piston heads.
^ When installing chain tensioners or other sliding parts, lubricate contacting surfaces with new engine oil.
^ Apply new engine oil to bolt threads and seat surfaces when installing the camshaft sprockets and the crankshaft pulley.
^ Do not spill engine coolant on the drive belts.
^ Please refer to the Service Manual for the correct tightening torque.
Removal
1. Set # 1 piston at TDC on its compression stroke.
2. Remove the spark plug wires.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 2
3. Remove the rocker cover (see Figure 1).
4. Remove the coolant reservoir tank with bracket and reposition it for clearance.
5. Support the engine with a suitable jack.
6. Remove cylinder head front mounting bracket.
7. Remove engine front mounting, then the engine front mounting bracket.
8. Remove cylinder head front cover.
9. Remove the upper chain tensioner (see Figure 2).
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 3
10. Wipe off the links of the upper timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with
the timing marks on the cam sprockets and idler sprocket (see Figure 3)
11. Remove the four (4) front cover to cylinder head bolts.
12. Remove side and lower engine compartment splash covers.
13. Remove the accessory drive belts.
14. Remove the crankshaft pulley.
15. Drain coolant by removing the cylinder block drain plug and opening the radiator drain **** (Refer to MA section of the Service Manual).
16. Drain engine oil.
17. Remove intake manifold support of engine front side.
18. Remove power steering pump, pump bracket and tension rod. Position pump aside for clearance.
19. Remove the thermostat housing (See Figure 4).
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 4
20. Remove the lower chain tensioner (see Figure 5).
21. Remove the front exhaust tube. Refer to the "FE" section (Exhaust System) of the Service Manual.
22. Remove the front and rear engine gussets (if equipped) on either side of the oil pan.
NOTE:
On A/T models, remove the rear plate cover.
23. Remove the oil pan (see Figure 6).
a. Insert the Tool between the cylinder block and oil pan.
CAUTION:
Be careful not to damage the aluminum mating face. Do not insert a screwdriver, or the oil pan flange will become damaged.
b. Slide the Tool by tapping it on the side of the Tool with a hammer.
24. Remove the A/C compressor and position it aside for clearance.
25. Remove the A/C and alternator bracket with the alternator.
26. Remove the oil pump drive spacer.
CAUTION:
Be careful not to scratch the drive spacer when removing it.
27. Remove the front cover bolts and front cover.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 5
CAUTION:
One bolt is located on the water pump (see Figure 7).
*1: Located on engine front mounting bracket.
*2: Located on the water pump.
*3: Located on the power steering oil pump adjusting bar.
CAUTION:
Be careful not to tear or damage the cylinder head gasket.
28. Remove the cylinder block to front cover alignment dowels.
CAUTION:
Do not hit the dowels or the cylinder block will crack.
29. Wipe off the links of the lower timing chain next to the timing marks on the sprockets. Put paint marks on the timing chain, matching them with
the timing marks on the idler sprocket and crankshaft sprocket (see Figure 8).
Installation
1. Install the crankshaft sprocket, making sure the mating marks face the front of the engine.
2. Install the idler sprocket and lower timing chain using the mating marks and the paint marks made during the removal process.
CAUTION:
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 6
Be careful not to tear or damage the cylinder head gasket.
3. Install the lower chain guides.
4. Front cover installation:
a. Using a scraper or other suitable tool remove all traces of liquid gasket from the cylinder block and front cover mating surfaces.
b. Install new crankshaft seal in front cover.
c. Install new oil passage O-rings and apply a continuous bead of RTV sealant to the front cover (see Figure 1).
NOTE:
Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
d. Install the front cover to the engine.
CAUTION:
Be careful not to tear or damage the cylinder head gasket or oil seal.
5. Align oil pump drive spacer with the oil pump, and install.
6. Install the oil strainer.
7. Install oil pan, referring to "Installation" in the "OIL PAN" section of the Service Manual.
8. Install upper timing chain and sprockets, using the painted reference marks made during removal.
9. Install upper chain tensioner.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 7
a. Before installing the chain tensioner, insert a suitable pin into the pin hole of the chain tensioner (see Figure 2) to hold the tensioner in.
b. Once the tensioner is installed, remove the pin.
10. Install the lower chain tensioner (See Figure 3).
NOTE:
Make sure the gasket is facing the proper direction before installing the tensioner.
CAUTION:
Now rotate the crankshaft by hand. Check that no binding or interference problems occur when the engine is rotated.
11. Install the thermostat housing.
a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the engine front cover and the thermostat housing.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 8
b. Apply a continuous bead of RTV sealant to the housing as shown in Figure 4.
NOTE:
Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
12. Install camshaft sprocket cover:
a. Use a scraper to remove all traces of liquid gasket from the mating surfaces of the cylinder head and camshaft sprocket cover.
b. Apply a continuous bead of RTV sealant to the cover as shown in Figure 5.
NOTE:
Use Genuine Nissan RTV silicone sealant P/N 999MP-A7007, Three Bond P/N TB1207D or equivalent.
d. Install camshaft sprocket cover.
1995 Nissan-Datsun 200SX L4-1597cc 1.6L DOHC MFI (GA16DE) Page 9
13. Apply RTV sealant to rocker cover gasket (see Figure 6a) and install rocker cover, tightening the bolts as shown in Figure 6b.
14. Install the following parts:
a. Crankshaft pulley.
b. A/C compressor and alternator bracket with alternator.
c. A/C compressor.
d. Power steering oil pump and tension rod.
15. Install front and rear engine gussets (if equipped), and rear cover plate (A/T models).
16. Install front exhaust tube.
17. Install upper right engine bracket and mount.
18. Install coolant reservoir tank.
19. Install alternator, power steering and A/C compressor drive belts.
20. Install engine compartment splash guards.
21. Install vacuum hoses, electrical harnesses and connectors.
22. Install spark plug wires.
23. Refill with coolant. Refer to the "MA" section ("Changing engine coolant, Engine Maintenance") of the Service Manual.
24. Refill with engine oil. Refer to the "MA" section ("Changing engine oil, Engine Maintenance") of the Service Manual.

Timing Chain & Gears Removal & Installation To Remove:
NOTE: Keep the cam chain away from magnetic fields.
Crankshaft set at TDC marks

1. Turn the crankshaft pulley so its Top Dead Center (TDC) mark (1) lines up with the pointer (2).
2. Raise and support the vehicle.
3. Remove the front tires/wheels. Front undercar splash shield
   
   
4. Remove the front undercar splash shield.
5. Remove the drive belt.
6. Remove the cylinder head cover (See section on Valve Cover).
7. Remove the crankshaft pulley (See section on Crankshaft Damper). CKP sensor and VTC solenoid electrical connectors
   
   
8. Disconnect the Crankshaft Position (CKP) sensor connector (1) and Variable Valve Timing Control (VTC) oil control solenoid valve connector (2).
9. Remove the VTC oil control solenoid valve (See section on VTC Solenoid Valve).
10. Support the engine with a jack and wood block under the oil pan. Ground cable and upper bracket removal
    
    
11. Remove the ground cable (1), and remove the upper bracket (2). Side engine mount bracket removal
    
    
12. Remove the side engine mount bracket. Timing chain cover removal
    
    
13. Remove the timing chain cover bolts both from the front to the block and from the bottom to the oil pan.
14. Remove the timing chain cover.
15. Loosely install the crankshaft pulley. Compress the timing chain auto-tensioner
    
    
16. Turn the crankshaft counterclockwise to compress the auto-tensioner. Lock the timing chain auto-tensioner
    
    
17. Align the holes on the lock (1) and the auto tensioner (2), and then insert a 0.06 inch (1.5 mm) diameter pin (3) into the holes.
18. Turn the crankshaft clockwise to secure the pin. Removal of the timing chain auto-tensioner
    
    
19. Remove the auto-tensioner. Removal of the timing chain guide B
    
    
20. Remove the cam chain guide B. Removal of the timing chain guide A
    
    
21. Remove the cam chain guide A (1) and tensioner arm (2).
22. Remove the cam chain.

Timing Chain and Sprockets REMOVAL & INSTALLATION 2.3L and 2.4L Engines The following tools will be required to perform this procedure:

• Camshaft sprocket timing alignment pins - J 36008 or equivalent
• Camshaft sprocket wrench - J 39579 or equivalent

2. Fig. 1: View of the DOHC engine "timed position'' - 2.3L and 2.4L engines
   Fig. 2: View of the SOHC engine "timed position'' - 2.3L engine
   
3. Remove the timing chain guides. There are usually three.
4. Raise and safely support the front of the vehicle.
5. Make sure all of the slack is above the tensioner. Gently pry off timing chain tensioner spring retainer, then remove the spring. NOTE: On the 2.3L engine two styles of tensioners are used. Early production engines will have a spring post and late production ones will not. Both styles are identical in operation and are interchangeable.
   
6. Remove the timing chain tensioner shoe retainer.
7. Make sure all the slack in the timing chain is above the tensioner assembly; remove the chain tensioner shoe. The timing chain must be disengaged from the wear grooves in the tensioner shoe in order to remove the shoe. Slide a suitable small prybar under the timing chain while pulling shoe outward.
8. If difficulty is encountered while removing chain tensioner shoe, proceed as follows:
   1. Lower the vehicle.
   2. Hold the intake camshaft sprocket with a camshaft sprocket wrench - J 39579 or equivalent holding tool and remove the sprocket bolt and washer.
   3. Remove the washer from the bolt and re-thread the bolt back into the camshaft by hand. The bolt provides a surface to push against.
   4. Remove intake camshaft sprocket using a 3-jaw puller in the 3 relief holes in the sprocket. NOTE: Do NOT try to pry the sprocket off the camshaft or damage to the sprocket or chain housing could occur.
      
9. Unfasten the tensioner assembly attaching bolts, then remove the tensioner. CAUTION
   The tensioner piston is spring loaded and could fly out causing personal injury. Use care when removing.
   
10. Matchmark the timing chain outer surface for reassembly purposes.
11. If equipped, remove the chain housing to block stud, which is actually the timing chain tensioner shoe pivot.
12. Remove the timing chain.
13. Inspect the parts for wear, then replace if necessary. Some scoring of the timing chain shoe and guides is normal. Clean the old sealant off of the bolt with a wire brush. Clean the threaded hole in the camshaft with a round nylon bristle brush. To install: WARNING
    Failure to following installation procedures can result in severe engine damage.
    
14. Install the intake camshaft sprocket onto the camshaft with the marked surface showing. Install the sprocket retaining bolt and washer. Use an adhesive compound 12345493 or equivalent on the bolt. Tighten the bolt to 52 ft. lbs. (70 Nm), while holding the sprocket with tool J-36013, J 39579 or equivalent, if removed.
15. Install tool J 36800 or equivalent, through hole(s) in the camshaft sprocket(s) into the holes in the timing chain housing. This positions the camshafts for correct timing. Fig. 3: Placing the camshaft sprockets onto the marked surface of the camshaft
    
16. If the camshafts are out of position and must be rotated more than 1?8 turn in order to install the alignment dowel pins:
    1. The crankshaft must be rotated 90°clockwise off of TDC in order to give the valves adequate clearance to open.
    2. Once the camshafts are in position and the dowels installed, rotate the crankshaft COUNTERCLOCKWISE back to TDC. NOTE: Do NOT rotate the crankshaft clockwise to TDC, or valve and piston damage could occur. WARNING
       The side of the timing chain that was marked must be facing outward when installed.
       
17. For DOHC engines only, install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket.
18. Remove the alignment dowel pin from the intake (DOHC only) camshaft. Using dowel pin remover tool J 39579 or equivalent, rotate the intake (DOHC only) camshaft sprocket counterclockwise enough to slide the timing chain over the intake (DOHC only) camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the two camshaft sprockets will tighten. If properly timed, the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. Fig. 4: Place the timing chain over the exhaust camshaft and around the idler sprocket and around the crankshaft sprocketDOHC engines
    
19. Leave the alignment dowel pins installed.
20. Raise and safely support the vehicle.
21. With slack removed from chain between intake camshaft sprocket (camshaft sprocket for SOHC engines) and crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain one tooth forward or rearward, remove the slack and recheck the marks.
22. If equipped, tighten the chain housing to block stud. The stud is installed under the timing chain. Tighten to 19 ft. lbs. (26 Nm).
23. For vehicles through 1991, reload timing chain tensioner assembly to its "zero'' position as follows:
    1. Assemble restraint cylinder, spring and nylon plug into plunger. Index slot in restraint cylinder with peg in plunger. While rotating the restraint cylinder clockwise, push the restraint cylinder into the plunger until it bottoms. Keep rotating the restraint cylinder clockwise but allow the spring to push it out of the plunger. The pin in the plunger will lock the restraint in the loaded position.
    2. Install tool J-36589 or equivalent, onto plunger assembly.
    3. Install plunger assembly into tensioner body with the long end toward the crankshaft when installed.
24. For 1992-98 vehicles, reload timing chain tensioner assembly to its "zero'' position as follows:
    1. Form a keeper from a piece of heavy gauge wire. See the accompanying figure.
    2. Apply slight force on the tensioner blade to compress the plunger.
    3. Insert a small prybar into the reset access hole, then pry the racket pawl away from the ratchet teeth while forcing the plunger completely in the hole.
    4. Install the keeper between the access hole and the blade. Fig. 5: View of reloading the timing chain tensioner assembly to its "zero'' position - 1992-98 vehicles
       
25. Install the tensioner assembly to the chain housing. Recheck the plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.
26. Install and tighten timing chain tensioner bolts. Tighten to 89 inch lbs. (10 Nm).
27. Install the tensioner shoe and tensioner shoe retainer. Remove the special tool J-36589, then squeeze the plunger assembly into the tensioner body to unload the plunger assembly.
28. Lower vehicle enough to reach and remove the alignment dowel pins.
29. Rotate crankshaft clockwise (normal rotation) two full rotations. Align the crankshaft keyway with the mark on the cylinder block, then reinstall the alignment dowel pins. The pins will slide in easily if the engine is timed correctly. WARNING
    If the engine is not correctly timed, severe engine damage could occur.
    
30. Install the timing chain guides and, if equipped, the crankshaft oil slinger.
31. Install the timing chain front cover. For details, please refer to the procedure located in this section.
32. Connect the negative battery cable, then start the engine and check for oil leaks.

The timing chain should of been changed at 30,000 or 60,000 miles it's in the owwners manual.

i had the same problem. had a knocking on the engine and let the vehicle sit until i had time to look for the problem. my unknowing mom took the car without permission and the car broke down on her. as it would turn out the upper timing guide rail broke off and damaged the cam gears and broke the upper timing chain along with damaging both the right and left lower chain guides, and the tensioner was also damaged. i would recommend that u inspect the lower chain to make sure that everything is good.