Oil Pan Installation Procedure
OIL PAN INSTALLATION PROCEDURETwo-Wheel Drive (2WD) and All-Wheel Drive (AWD)
1. Apply a 5.5 mm (0.21 in) bead of Mazda Gray RTV Silicone Gasket Maker to the 2 engine front cover-to-cylinder block joint areas on the sealing surface of the oil pan.
2. Apply a 5.5 mm (0.21 in) bead of Mazda Gray RTV Silicone Gasket Maker to the engine front cover-to-oil pan mating surface.
3. Apply a 3 mm (0.11 in) bead of Mazda Gray RTV Silicone Gasket Maker to the sealing surface of the oil pan-to-engine block mating surface.
NOTE:
^ Failure to use Mazda Gray RTV Silicone Gasket Maker may cause the engine oil to foam excessively and result in serious engine damage.
^ The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out within 60 minutes of sealant application.
4. Apply a 5.5 mm (0.21 in) bead of Mazda Gray RTV Silicone Gasket Maker to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
5. With the help from an assistant, install the oil pan and bolts 10, 11, 13 and 14 finger tight.
NOTE:
^ The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant application.
^ Keep the oil pan as close as possible to the transmission while installing, then slide forward towards the engine front cover to prevent wiping off of the sealant.
6. Install the A/C compressor bolt.
^ Hand tighten the bolt.
7. Thighten bolts 10, 11, 13, and 14 in the sequence shown to 3 Nm (27 in-lbf).
8. Install the 4 lower engine front cover bolts.
^ Do not torque at this time.
9. Install the remaining oil pan bolts and tighten in the four steps shown.
^ Step 1 - Tighten all bolts in sequence to 3 Nm (27 in-lbf).
^ Step 2 - Loosen all bolts 180 degrees.
^ Step 3 - Tighten bolts 1 through 14 in sequence to 20-28 Nm (15-20 ft-lbf).
^ Step 4 - Tighten bolts 15 and 16 to 8.5 - 11.5 Nm (76 - 101 in-lbf).
10. Tighten the 4 lower engine front cover bolts in two steps.
^ Step 1 - Tighten bolts to 10 N-m (89 in-lbf).
^ Step 2 - Tighten bolts to 20-28 N-m (15-20 ft-lbf).
11. Install the RH engine splash shield.
12. Tighten the A/C compressor bolt to 24-36 N-m (18-26 ft-lbf).
13. Remove the wedge between the transmission and engine block and draw the bellhousing up to the engine by tightening the LH bellhousing-to-engine bolt.
^ Do not tighten at this time.
14. Draw the bellhousing up to the engine by tightening the RH engine-to-bellhousing bolt.
^ Do not tighten at this time.
15. Install the Warm Up Three Way Catalytic Converter LH bracket (A).
16. Install the 4 oil pan-to-bellhousing bolts.
^ Do not tighten at this time.
17. Tighten the 4 oil pan-to-bellhousing bolts to 37-52 N-m (28-38 ft-lbf).
18. Tighten the RH engine-to-bellhousing bolt to 37-52 N-m (28-38 ft-lbf).
19. Tighten the 3 LH bellhousing-to-engine bolts to 37-52 N-m (28-38 ft-lbf).
20. Install the ATF cooler. Tighten bolts to 19-25 N-m (2.0-2.5 kgf-m, 14-18 ft-lbf).
21. Install the inspection cover and the 2 fasteners.
All-Wheel Drive (AWD) - Steps 22-27 are for AWD only
22. Install the Transfer assembly (A). Refer to MS3 online or Workshop Manual (section 01-13 TRANSFER REMOVAL/INSTALLATION).
23. Install the Transfer assembly support bracket.
^ Tighten the 5 Transfer bracket bolts to 70 N-m (52 ft-lb).
24. Install the RH catalytic converter with new upper exhaust gasket (P/N CY01-40-450). For additional information refer to MS3 online or Workshop Manual (section 01-13 EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7]).
25. Install the RH drive shaft and RH wheel in reverse order.
^ Tighten the 2 drive shaft support nuts to 40 N-m (30 ft-lb).
^ Install new RH hub nut, tighten to 235.2 - 274.4 N-m (173.5 - 202.3 ft-lb) and stake it.
CAUTION:
The sharp edges of the drive shaft can slice or puncture the oil seals. Be careful when installing the drive shaft into the transaxle.
26. If necessary, top off Transfer oil with SAE 75W-140 Premium High Performance Rear Axle Lubricant (0000-77-W140-QT). Refer to MS3 online or Workshop Manual (section 03-16 TRANSFER OIL INSPECTION).
Two-Wheel Drive (2WD) and All-Wheel Drive (AWD)
27. Tighten the 3 upper bellhousing-to-engine bolts to 37-52 N-m (28-38 ft-lbf).
28. Install the harness bracket and tighten the bolts to 8-10 N-m (71-88 in-lbf).
29. Install the starter fixing bolt. Tighten bolt to 27 N-m (2.8 kgf-m, 20 ft-lbf).
30. Install a new engine oil filter.
^ Install the oil filter until the 0-ring contacts the sealing surface.
^ Tighten the oil filter 3/4 turns by hand.
NOTE:
Do not lubricate the engine oil filter gasket.
31. Install the No. 1 engine mount bracket bolts (A) and (B) in order of (A) => (B). Tighten the bolts to 93.1 - 116.6 N-m (9.5 - 11.8 kgf-m, 68.7 - 85.9 ft-lbf)
32. Install the exhaust front pipe (A) with new (C), (D) and (E) exhaust gaskets.
33. Lower the vehicle.
34. Remove the engine support kit SST 49C0-17-5A0 and support hanger SST 49L0-17-5A0.
35. Install the following parts after removing the SST.
a. Install the front cooler pipe fixing bolt (A). Tighten bolt to 8-12 N-m (82-122 kgf-cm, 71-106 in-lbf)
b. Install the cowl panel. Refer to MS3 online or Workshop Manual (section 09-10 COWL PANEL REMOVAL/INSTALLATION).
c. Install the cowl grille. Refer to MS3 online or Workshop Manual (section 09-16 COWL GRILLE REMOVAL/INSTALLATION).
d. Install the windshield wiper arm and blade. Refer to MS3 online or Workshop Manual (section 09-19 WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION).
36. Install the oil level indicator.
37. Install the battery tray. For additional information, refer to MS3 online or Workshop Manual (section 01-13 BATTERY REMOVAL/INSTALLATION [MZI-3.7]).
38. Install the Air Cleaner Case. For additional information, refer to MS3 online or Workshop Manual (section 01-13 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7]).
39. Fill the engine with clean engine oil.
NOTE:
2007-2009 CX-9 vehicles, refer to TSB 01-044/08 for engine oil level service caution.