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Engine Disassembly/Assembly: Notes

WARNING: This page is about a different variant/trim than selected.
CAUTION:
  • When the transaxle is installed, do not suspend the engine. Otherwise, the SST installation area of the cylinder head may be damaged due to excess weight. Only suspend the engine after separating the engine and transaxle.
  • Applying excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the electric variable valve timing motor/driver may cause a malfunction. When servicing, be careful not to apply excessive force to the electric variable valve timing motor/driver using other parts or tools.
  1. Install the SST using part number 99794 1025 or an M10 x 1.25, length 25 mm {0.98 in} bolt as shown in the figure below.

    Engine front side

    Fig 1: SST Using Part Number (99794 1025) Or Bolt - Engine Front Side
    G12188513Courtesy of MAZDA MOTORS CORP.

    Engine rear side

    Fig 2: SST Using Part Number (99794 1025) Or Bolt - Engine Rear Side
    G11429767Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}

  2. Engage the hooks of the SST (49 L017 5A0) to the SST (49 UN30 3050).
    Fig 3: Engaging Hooks Of SST (49 L017 5A0) To SST (49 UN30 3050)
    G11429768Courtesy of MAZDA MOTORS CORP.
  3. To ensure the safety of the work (control engine and transaxle sway), set a hoist as shown in the figure below.
    CAUTION:
    • Do not lift up the engine.
    Fig 4: Setting Hoist
    G11429769Courtesy of MAZDA MOTORS CORP.
  4. Remove the insulators using the following procedure:
    1. Disconnect the A/F sensor connector and clip shown in the figure below.
      Fig 5: Disconnecting A/F Sensor Connector And Clip
      G12188517Courtesy of MAZDA MOTORS CORP.
    2. Remove the insulator shown in the figure below.
      Fig 6: Insulator And Nut With Torque Specification
      G12188518Courtesy of MAZDA MOTORS CORP.
    3. Remove the insulator shown in the figure below.
    Fig 7: Insulator And Bolt With Torque Specification
    G12188519Courtesy of MAZDA MOTORS CORP.
  5. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  6. Remove the exhaust manifold bracket using the following procedure:
    1. Loosen the bolt shown in the figure below.
      Fig 8: Exhaust Manifold Bracket, Cylinder Block, Bolt And Transaxle (ATX)
      G11429772Courtesy of MAZDA MOTORS CORP.
    2. Remove the bolts in the order shown in the figure below, then remove the exhaust manifold bracket.
    Fig 9: Exhaust Manifold Bracket (ATX) Bolts Loosening Sequence
    G11429774Courtesy of MAZDA MOTORS CORP.
    • When installing, install the exhaust manifold bracket using the following procedure:
    1. Temporarily tighten the exhaust manifold bracket installation bolts in the order as shown in the figure below.
      Fig 10: Exhaust Manifold Bracket (ATX) Bolts Tightening Sequence
      G11429776Courtesy of MAZDA MOTORS CORP.
    2. Loosen the bolt shown in the figure below until it is no longer seated on the surface.
      Fig 11: Exhaust Manifold Bracket, Cylinder Block, Bolt And Transaxle (ATX)
      G11429772Courtesy of MAZDA MOTORS CORP.
    3. Tighten the bolt in the order shown in the figure below.
    Fig 12: Exhaust Manifold Bracket (ATX) Bolts Tightening Sequence
    G11429780Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf}

  7. Remove the bracket No. 1 (drive shaft bracket). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  8. Remove the starter. (See STARTER REMOVAL/INSTALLATION .)
  9. Remove the coolant control valve. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION .)
  10. Fix the drive plate using the crankshaft pulley lock bolt.
  11. Remove the torque converter installation nut from the starter installation hole. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION .)
  12. Disconnect the engine and transaxle, and lower only the engine from the engine lifter. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION .)
  13. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION)] .)
  14. Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  15. Remove the oil separator. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION .)
  16. Remove the knock sensor (KS). (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION .)
  17. Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION .)
  18. Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION .)
  19. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5] .)
  20. Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION .)
  21. Remove the electric variable valve timing motor/driver. (See ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION .)
  22. Remove the OCV for No. 1 cylinder deactivation. (See OIL CONTROL VALVE (OCV) FOR CYLINDER DEACTIVATION REMOVAL/INSTALLATION .)
  23. Remove the OCV for No. 4 cylinder deactivation. (See OIL CONTROL VALVE (OCV) FOR CYLINDER DEACTIVATION REMOVAL/INSTALLATION .)
  24. Remove the oil filter. (See OIL FILTER REPLACEMENT .)
  25. Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION .)
  26. Remove the engine oil temperature sensor/engine oil pressure sensor. (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION .)
  27. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION .)
  28. Remove the dipstick.
  29. Remove the purge solenoid valve, catch tank and bracket as a single unit. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  30. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION .)
  31. Remove the wiring harness bracket using the following procedure:
    1. Remove the clip shown in the figure below.
      Fig 13: Wiring Harness Clip, Wiring Harness Bracket And Engine Front Cover
      G12188525Courtesy of MAZDA MOTORS CORP.
    2. Remove the bolts shown in the figure below.
    Fig 14: Wiring Harness Bracket, Engine Front Cover And Bolts With Torque Specification
    G12188526Courtesy of MAZDA MOTORS CORP.
  32. Remove the wiring harness bracket and wiring harness protector shown in the figure below.
    Fig 15: Wiring Harness Bracket And Wiring Harness Protector
    G12228326Courtesy of MAZDA MOTORS CORP.
  33. Remove the emission harness.
  34. Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  35. Remove the water inlet pipe and flange component. (See CYLINDER HEAD GASKET REPLACEMENT .)
  36. Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION .)
  37. Remove the short cord of the engine oil level sensor. (See ENGINE OIL LEVEL SENSOR REMOVAL/INSTALLATION .)
  38. Remove in the order indicated in the table.
  39. Assemble in the reverse order of disassembly.
Fig 16: Oil Filter Body And Exhaust Manifold Bracket With Torque Specification
G12228327Courtesy of MAZDA MOTORS CORP.
COMPONENT DESCRIPTION

1 Oil filter body
(See Oil Filter Body Installation Note .)
2 Exhaust manifold bracket
(See Exhaust Manifold Bracket Installation Note .)
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