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Engine Disassembly/Assembly: Notes

WARNING: This page is about a different variant/trim than selected.

Special Service Tool (SST) 

  1. Mazda SST number
  2. Global SST number
  1. 49 UN30 3050
  2. 303-050

Engine lifting bracket
G13713016Courtesy of MAZDA MOTORS CORP.
  1. 49 L017 5A0
  2. -

Support hanger
G13713017Courtesy of MAZDA MOTORS CORP.

Replacement Part 

Gasket
Quantity: 1
Location of use: Oil filter body		 Gasket
Quantity: 1
Location of use: Water outlet component
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. To enable installation of the SST, remove the bolts and clip shown in the figure and set the wiring harness bracket aside.
    G13713018Courtesy of MAZDA MOTORS CORP.
  2. Remove the protector.
    G13713019Courtesy of MAZDA MOTORS CORP.
  3. Install the SST using part number 99794 1025 or an M10-1.25, length 25 mm {0.98 in} bolt as shown in the figure.

    Engine front side 

    Fig 1: Intake Manifold, SST Bolt With Torque Specification (Engine Front Side)
    G13713020Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Slots have been adopted for the No. 3 engine mount installation holes. If the No. 3 engine mount is deviated from the original position when installing the No. 3 engine mount, engine noise or vibration could increase. Before removing the No. 3 engine mount, place alignment marks on the No. 3 engine mount and body so that they can be assembled to the same positions as before removal.

      Engine rear side 

    Fig 2: Vacuum Pump, Engine Hanger, SST Bolt With Torque Specification (Engine Rear Side)
    G13713021Courtesy of MAZDA MOTORS CORP.
  4. Engage the hooks of the SST (49 L017 5A0) to the SST (49 UN30 3050).
    G13107103Courtesy of MAZDA MOTORS CORP.
  5. To ensure the safety of the work (control engine and transaxle sway), set a hoist as shown in the figure.
    G11436610Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not lift up the engine.
  6. Remove the WU-TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  7. Remove the dynamic pressure turbo. (See DYNAMIC PRESSURE TURBO REMOVAL/INSTALLATION .)
  8. Remove the oil cooler. (See OIL COOLER REMOVAL/INSTALLATION .)
  9. Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  10. Remove the starter. (See STARTER REMOVAL/INSTALLATION .)
  11. Fix the drive plate using the crankshaft pulley lock bolt.
  12. Remove the torque converter installation nut from the starter installation hole (if necessary).
  13. Disconnect the engine and transaxle, and lower only the engine from the engine lifter (if necessary.
  14. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION .)
  15. Remove the EGR cooler. (See EGR COOLER REMOVAL/INSTALLATION .)
  16. Remove the bolts shown in the figure.
    Fig 3: Bracket Bolts With Torque Specification
    G13713024Courtesy of MAZDA MOTORS CORP.
  17. Remove the water pipe component and oil cooler pipe component. (See CYLINDER HEAD GASKET REPLACEMENT .)
  18. Remove the flange and water inlet pipe. (See CYLINDER HEAD GASKET REPLACEMENT .)
  19. Remove the following parts as a single unit: (Except U. S. A. and CANADA) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
    • Breather hose
    • Turbocharger air inlet hose
    • Ventilation pipe
  20. Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
    • Intake-air system
    • EGR valve
    • EGR pipe No. 2
  21. Remove the oil separator. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION .)
  22. Remove the knock sensor (KS). (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION .)
  23. Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION .)
  24. Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION .)
  25. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION .)
  26. Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION .)
  27. Remove the electric variable valve timing motor/driver. (See ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION .)
  28. Remove the drive belt auto tensioner. (See DRIVE BELT AUTO TENSIONER REMOVAL/INSTALLATION .)
  29. Remove the oil filter. (See OIL FILTER REPLACEMENT .)
  30. Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION .)
  31. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION .)
  32. Remove the dipstick.
  33. Remove the purge bracket component, vacuum pipe component and air pipe component. (See TIMING CHAIN REMOVAL/INSTALLATION .)
  34. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION .)
  35. Remove the wiring harness bracket shown in the figure.
    Fig 4: Wiring Harness Bracket Bolts With Torque Specification
    G13713025Courtesy of MAZDA MOTORS CORP.
  36. Remove the emission harness.
  37. Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  38. Remove the water pump component. (See WATER PUMP REMOVAL/INSTALLATION .)
  39. Remove in the order indicated in the table.
  40. Assemble in the reverse order of disassembly.
Fig 5: Oil Filter Body Components With Torque Specification
G13713026Courtesy of MAZDA MOTORS CORP.
PART DESCRIPTION

1 Water outlet component
2 Insulator
3 Oil filter body
(See OIL FILTER BODY INSTALLATION NOTE .)
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