ENGINE DISASSEMBLY/ASSEMBLY [SKYACTIV-D 2.2]

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Special Service Tool (SST)

1.  : Mazda SST number
2.  : Global SST number
1: 49 UN30 3050
2: 303–050
 
Engine lifting bracket
1: 49 L017 5A0
2: –
 
Support hanger

Replacement Part

Gasket
 
Quantity: 2
 
Location of use: Water pipe A
Gasket
 
Quantity: 1
 
Location of use: Water pipe B
Bolt
 
Quantity: 2
 
Location of use: Noise suppression cover (No.3)
Gasket
 
Quantity: 1
 
Location of use: Oil pipe
Air hose
 
Quantity: 2
 
Location of use: Exhaust gas pressure sensor No.2
Clip
 
Quantity: 2
 
Location of use: Exhaust gas pressure sensor No.2

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.

1.  Remove the adapter.

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2.  Install the SST to the position shown in the figure using the following bolt and washer.

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Bolt: part number 99794 1025 or an M10 x 1.25, length 25 mm {0.98 in}
Washer: approx. 3 mm {0.1 in} thickness
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

3.  Install the SST to the position shown in the figure using the following bolt.

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Bolt: part number 99794 1025 or an M10 x 1.25, length 25 mm {0.98 in}
Tightening torque
38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

4.  Engage the hooks of the SST (49 L017 5A0) to the SST (49 UN30 3050).

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Caution
•  Do not lift up the engine.

5.  To ensure the safety of the work (control engine and transaxle sway), set a hoist as shown in the figure.

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6.  Remove the catalytic converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

7.  Remove the transfer bracket and transfer. (4WD) (See TRANSFER REMOVAL/INSTALLATION [GW6AX-EL].)

8.  Remove the turbocharger. (See TURBOCHARGER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Remove the exhaust gas temperature sensor No.1. (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Remove the exhaust gas pressure sensor No.1 component. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

11.  Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

12.  Remove the following emission system related parts:

•  EGR cooler bypass valve (See EGR COOLER BYPASS VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  EGR pipe (See EGR PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  EGR valve (See EGR VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  EGR cooler (See EGR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

13.  Remove the bracket No.1. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

14.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

15.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

16.  Remove the drive belt auto tensioner. (See DRIVE BELT AUTO TENSIONER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

17.  Remove the water pump, water pump housing and coolant control valve as a single unit. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

18.  Remove the thermo valve. (See THERMO VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

19.  Lock the drive plate against rotation using the crankshaft pulley lock bolt.

20.  Remove the torque converter installation nut from the starter installation hole. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6A-EL] (2WD).) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6AX-EL] (4WD).)

21.  Disconnect the engine and transaxle, and lower only the engine from the engine lifter. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6A-EL] (2WD).) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [GW6AX-EL] (4WD).)

22.  Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

23.  Remove the following fuel system related parts:

•  Injection pipes (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Fuel injectors (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Supply pump (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Lower case (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Common rail (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

24.  Remove the glow plugs. (See GLOW PLUG REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

25.  Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

26.  Remove the oil cooler. (See OIL COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

27.  Remove the oil filter. (See OIL FILTER REPLACEMENT [SKYACTIV-D 2.2].)

28.  Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

29.  Remove the following control system related parts:

•  CMP sensor (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  Engine oil temperature sensor/engine oil pressure sensor (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  ECT sensor (See ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
•  CKP sensor (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

30.  Remove the short cord of the engine oil level sensor. (See ENGINE OIL LEVEL SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

31.  Disassemble in the order indicated in the table.

32.  Assemble in the reverse order of disassembly.

Step 1

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1
Exhaust gas pressure sensor No.2 component
2
Oil pipe (cylinder head side)
3
Water pipe A
4
Water pipe B
5
Noise suppression cover (No.3)
6
Seal rubber

Step 2

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1
Water hose
2
Noise suppression cover (No.1), noise suppression cover (No.2), seal rubber
(See Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Removal Note.)
(See Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Installation Note.)


Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Removal Note

1.  Remove the noise suppression covers and seal rubbers in the order shown in the figure.

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2.  Remove the wiring harness using the following procedure:

(1)  Remove the wiring harness bracket installation bolts shown in the figure.
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(2)  Remove all of the related wiring harness clip.

3.  Remove the seal rubber (No.3).

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Noise Suppression Cover (No.1), Noise Suppression Cover (No.2), Seal Rubber Installation Note

1.  Temporarily put the seal rubber (No.3) on the engine front cover.

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2.  Install the wiring harness and wiring harness bracket using the following procedure:

Note
•  The seal rubber (No.3) can be fixed by installing the wiring harness bracket.
(1)  Install all of the related wiring harness clip.
(2)  Tighten the wiring harness bracket installation bolts shown in the figure.
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Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}
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Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Caution
•  Be careful that the covers and seal rubbers do not get hung up on the noise suppression cover installation bolts.

3.  Install the noise suppression covers and seal rubbers in the order shown in the figure.

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