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Engine Front Cover Installation Note

NOTE:
  • For a new engine front cover, the positioning pins in the two locations shown in the figure below project to the outside of the engine.
G14588066Courtesy of MAZDA MOTORS CORP.
  1. If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.
    G13149269Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • If a bolt with silicone sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.
    G16327513Courtesy of MAZDA MOTORS CORP.
  2. When reusing an engine front cover installation bolts, remove silicone sealant adhering to the bolts.
    CAUTION:
    • If oil, dirt, and sealant remain on the silicone sealant application surface and the step bead, the silicone sealant will not seal which will cause oil leakage.
    G16327514Courtesy of MAZDA MOTORS CORP.
  3. Completely clean and remove oil, dirt, silicone sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.
  4. Degrease the silicone sealant application surface and the step bead.
    CAUTION:
    • Apply the silicon sealant in a single, unbroken line.
    • To prevent silicone sealant from hardening, adhere the engine front cover and the cylinder block firmly within 10 min. after applying silicone sealant. After adhering them, tighten the installation bolts immediately.
    • Do not apply silicone sealant to the step bead.
  5. Apply silicone sealant (TB1217D) to the engine front cover according to the directions shown in the figure below.
    G14588070Courtesy of MAZDA MOTORS CORP.

    Bead thickness 

    1. 2-6 mm {0.1-0.2 in}
    2. 4-6 mm {0.16-0.23 in}
    3. 4-8 mm {0.2-0.3 in}
    CAUTION:
    • Apply the silicone sealant so that it goes into the cylinder head gasket.
  6. Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure below.
    G14588071Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not apply engine coolant to the O-ring (1). Otherwise, the O-ring could swell causing a seal malfunction.
      G14588072Courtesy of MAZDA MOTORS CORP.
    • Do not apply oil (such as engine oil, ATF) to the O-ring (2). Otherwise, the O-ring could swell causing a seal malfunction.
  7. Install a new O-ring to the O-ring installation groove of the engine front cover.
  8. Install the engine front cover to the engine.
    NOTE:
    • Temporarily install an appropriate bolt to the drive belt auto tensioner installation bolt hole to prevent:
      • A silicone sealant adhesion malfunction in the drive belt auto tensioner installation bolt hole.
      • A bolt mis-installation due to silicone sealant hardening.
    G14588073Courtesy of MAZDA MOTORS CORP.
  9. Prepare an appropriate M8 x 1.25 bolt (length 40 mm {1.6 in}).
    CAUTION:
    • For the number 3 bolt of the tightening order, install the bolt with new washer.
  10. Tighten the engine front cover installation bolts in the order shown in the figure below.
    Fig 1: Engine Front Cover Installation Bolts Tightening Sequence
    G14588074Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf}

  11. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.
  12. Return the engine wiring harness to its original position using the following procedure.
    1. Connect or install the following parts.

      Step 1 

      Fig 2: Wiring Harness Clips, Connectors And Bolt With Torque Specifications (Step 1)
      G14588075Courtesy of MAZDA MOTORS CORP.
      COMPONENT OPERATIONS

      Component no. Refer to
      1 Bolt
      2 Wiring harness clip
      3 Wiring harness clip
      4 Crankshaft position (CKP) sensor connector
      5 Engine oil solenoid valve connector
      6 A/F sensor connector
      7 Oil pressure switch connector

      Step 2 

      Fig 3: Wiring Harness Clip And Wiring Harness Protector Installation Nut With Torque Specifications (Step 2)
      G14588076Courtesy of MAZDA MOTORS CORP.
      COMPONENT OPERATIONS

      Component no. Refer to
      1 Wiring harness clip
      2 Wiring harness clip
      3 Wiring harness protector installation nut
    2. Install the throttle body. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.0] .)
    3. Connect or install the following parts.
      Fig 4: Wiring Harness Clip, Connectors And Bolt With Torque Specifications
      G14588077Courtesy of MAZDA MOTORS CORP.
      COMPONENT OPERATIONS

      Component no. Refer to
      1 High pressure fuel pump connector
      2 Exhaust camshaft position sensor connector
      3 Intake camshaft position sensor connector
      4 Wiring harness clip
      5 Bolt
    4. Connect the purge solenoid valve connector. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.0] .)
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