TIMING CHAIN REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

id0110s5801000

Special Service Tool (SST)

1.  : Mazda SST number 2.  : Global SST number
1: 49 UN30 3050 2: 303–050   Engine lifting bracket		1: 49 C017 5A0 2: –   Engine support set		1: 49 L017 5A0 2: –   Support hanger
1: 49 JP01 001 2: –   Holder		—		—

Replacement Part

Oil and Chemical Type

Operation After Replacing Timing Chain

1.  After replacing the timing chain, perform the following procedure.

STEP	ACTION	PAGE/CONDITION
1	Perform KOEO self-test procedure.	(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
2	Start the engine.	—
3	Verify that the check engine light does not illuminate.	—
4	Perform KOER self-test procedure.	(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
5	Perform timing chain learning procedure.	(See TIMING CHAIN LEARNING [SKYACTIV-D 2.2].)
6	Clear the DTCs.	(See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [PCM (SKYACTIV-D 2.2)].)
7	Switch the ignition off.	—
8	Wait for 30 s or more.	—

Timing Chain Removal/Installation

Warning

•  A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.

Caution

•  When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage the rocker arm. To prevent damage to the rocker arm when holding the camshaft on the cast hexagon, use a wrench on the rear side of the engine as shown in the figure to secure a clearance between the cam.

ac5wzw00006607

Note

•  Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

ac5uuw00008427

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Remove the front under cover No.2. (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

4.  Remove the front splash shield (RH). (See SPLASH SHIELD REMOVAL/INSTALLATION.)

5.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

7.  Drain the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-D 2.2].)

8.  Remove the oil pan. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

9.  Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

11.  Remove in the order indicated in the table.

12.  Install in the reverse order of removal.

13.  Refill with the specified type and amount of the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-D 2.2].)

14.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

15.  Inspect for engine coolant leakage. (See ENGINE COOLANT LEAKAGE INSPECTION [SKYACTIV-D 2.2].)

16.  If the timing chain is replaced, perform “Operation After Replacing Timing Chain”. (See Operation After Replacing Timing Chain.)

17.  Start the engine and inspect the following:

•  Leakage of engine oil.

•  Oil level (See ENGINE OIL LEVEL INSPECTION [SKYACTIV-D 2.2].)

•  Runout and contact of pulley and belt.

•  Idle speed (See ENGINE TUNE-UP [SKYACTIV-D 2.2].)

ac8wzw00002497

1	Dipstick
2	Cylinder head cover (See Cylinder head cover removal note.) (See Cylinder head cover installation note.)
3	Oil shower pipe (See Oil shower pipe installation note.)
4	Crankshaft pulley lock bolt (See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 2.2].)
5	Crankshaft pulley (See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 2.2].)
6	Front oil seal (See FRONT OIL SEAL REPLACEMENT [SKYACTIV-D 2.2].)
7	No.3 engine mount (See No.3 engine mount removal note.) (See No.3 engine mount installation note.)
8	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.)
9	Water pipe
10	Engine front cover (See Engine front cover removal note.) (See Engine front cover installation note.)
11	Timing chain tensioner (See Timing chain removal note.) (See Timing chain installation note.)
12	Timing chain tensioner arm (See Timing chain removal note.) (See Timing chain installation note.)
13	Timing chain guide (See Timing chain removal note.) (See Timing chain installation note.)
14	Timing chain (See Timing chain removal note.) (See Timing chain installation note.)
15	Crankshaft sprocket (See Timing chain removal note.) (See Timing chain installation note.)
16	Oil pump chain tensioner No.2 (See Oil pump chain removal note.) (See Oil pump chain installation note.)
17	Oil pump chain tensioner No.1 (See Oil pump chain removal note.) (See Oil pump chain installation note.)
18	Oil pump driven sprocket installation bolt (See Oil pump chain removal note.) (See Oil pump chain installation note.)
19	Oil pump driven sprocket (See Oil pump chain removal note.) (See Oil pump chain installation note.)
20	Oil pump chain (See Oil pump chain removal note.) (See Oil pump chain installation note.)
21	Oil pump drive sprocket
22	Key

Cylinder head cover removal note

1.  Remove the fuel feed pipe. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

2.  Remove the injection pipe (supply pump side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

3.  Set the wiring harness and ground cable aside using the following procedure:

(1)  Remove the adapter shown in the figure.

ac5uuw00008429

(2)  Remove the nuts shown in the figure.

ac5uuw00008430

(3)  Disconnect the connectors and clip shown in the figure.

ac8wzw00002498

(4)  Remove the clips shown in the figure.

ac8wzw00002499

ac5wzw00009353

4.  Set the exhaust gas temperature sensor No.1 bracket aside.

ac8wzw00002500

5.  Set the lower case and fuel hose bracket aside using the following procedure:

(1)  Disconnect the vacuum hose from the vacuum pump.

(2)  Remove the fuel return hose No.4. (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(3)  Remove the wiring harness protector from the fuel hose bracket.

ac8wzw00002501

(4)  Remove the bolts and nut shown in the figure.

ac5wzw00009355

(5)  Set the lower case and the fuel hose bracket aside to the left side of the vehicle with the fuel main hose and return hose No.1 connected.

6.  Remove the cylinder head cover.

No.3 engine mount removal note

1.  Remove the clip and bolt shown in the figure and set the ground cable aside.

ac8wzw00002502

2.  Disconnect the active bonnet actuator connector (RH). (See ACTIVE BONNET ACTUATOR REMOVAL/INSTALLATION.)

3.  Remove the bolts shown in the figure and set the PCM component aside with the PCM connector connected.

ac8wzw00002503

4.  Remove the wiring harness bracket.

ac8wzw00002504

5.  Remove the adapter shown in the figure.

ac5wzw00009361

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

ac5wzw00006590

7.  Remove the following parts.

(1)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

(2)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(3)  Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

(4)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

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

ac5wzw00006591

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.

9.  Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.

ac5wzw00009362

Note

•  Paint so that the No.3 engine mount is framed on the body side and the outline of the nut is framed on the No.3 engine mount side.

10.  Install the SST using the following procedures.

Caution

•  Refer to the SST instruction manual for the basic handing procedure.

Note

•  Install front foot No. 2 to the left and right front shafts of the SST.

ac5wzw00009363

(1)  Protect the positions shown in the figure using tape.

ac5wzw00009364

(2)  As shown in the figure, set the rear shafts of the SST to the left and right shock absorber nuts.

ac5wzw00009365

(3)  As shown in the figure, set the front shafts of the SST to the left and right bolts.

ac5wzw00009366

(4)  Install the SST (49 L017 5A0) to the SST (49 C017 5A0) as shown in the figure.

ac5jjw00009739

(5)  Install the SST (49 L017 5A0) to the SST (49 UN30 3050) with the hook of the SST (49 L017 5A0) facing outward.

ac5jjw00009740

(6)  Adjust the height of the left and right side bars so that they are leveled, then tighten each part of the SST.

(7)  Apply tension to the chain to secure the engine.

11.  Remove the No.3 engine mount.

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.

ac5uuw00008436

2.  Remove the water pipe installation bolt shown in the figure.

ac8wzw00002505

3.  Disconnect the connectors shown in the figure.

ac8wzw00002506

•  Connector A: Exhaust gas temperature sensor No.2 connector

•  Connector B: A/F sensor connector

•  Connector C: Exhaust gas temperature sensor No.3 connector

4.  Remove the connectors, clips, and bolts shown in the figure and set the wiring harness and wiring harness bracket aside.

ac8wzw00002507

•  Connector A: Engine oil solenoid valve connector

•  Connector B: CKP sensor connector

5.  Remove the seal rubber (No.3) shown in the figure.

ac8wzw00002508

Engine front cover removal note

1.  Remove the engine front cover installation bolts.

Caution

•  Do not apply excessive force to the screwdriver. Otherwise, the engine front cover could be damaged.

•  Be careful not to scratch or damage the seal surface. Otherwise, it could cause oil leakage.

2.  Using a screwdriver wrapped in a rag, peel the silicone sealant away a little at a time, and remove the engine front cover.

ac5wzw00005988

ac5wzw00005989

Timing chain removal note

1.   Rotate the crankshaft clockwise to adjust the timing marks and the key position as shown in the figure, and set cylinder No.1 at top dead center (TDC).

ac5wzw00005990

2.  Release the tension on the timing chain using the following procedure:

(1)  Insert a wire with an approx. diameter of 1.4 mm {0.055 in} or a paper clip into the body hole of the timing chain tensioner.

ac5wzw00005991

(2)  Press the timing chain in the direction of the arrow and press on the plunger of the timing chain tensioner.

ac5wzw00005566

(3)  Press the wire or paper clip set in Step (1) further with the plunger pressed.

ac5wzw00005992

Note

•  The wire or paper clip secures the plunger, and the tension can be released.

3.  Remove the timing chain tensioner and timing chain tensioner arm.

4.  Remove the timing chain guide.

5.  Remove the timing chain and crankshaft sprocket as a single unit.

Oil pump chain removal note

1.  Verify that the oil pump driven sprocket alignment marks and key are aligned to the positions shown in the figure.

ac5uuw00009337

2.  Release the tension on oil pump chain using the following procedure.

(1)  Press in the plunger of oil pump chain tensioner No.2 as shown in the figure using a screwdriver wrapped in a cloth.

ac5uuw00009338

(2)  Insert a wire or paper clip into the shoe hole with the plunger pressed in.

ac5uuw00009339

Note

•  When inserting a wire or paper clip, the shoe is fixed with the plunger pressed in.

(3)  Press in the plunger of oil pump chain tensioner No.1 as shown in the figure using a screwdriver wrapped in a cloth.

ac5uuw00009340

(4)  Insert a wire or paper clip into the shoe hole with the plunger pressed in.

ac5uuw00009341

Note

•  When inserting a wire or paper clip, the shoe is fixed with the plunger pressed in.

3.  Remove the oil pump chain tensioner No.1 and No.2.

4.  Remove the oil pump driven sprocket installation bolt using the following procedure.

(1)  Lock the oil pump driven sprocket against rotation using the SST.

ac8jjw00000508

(2)  Remove the oil pump driven sprocket installation bolt.

5.  Remove the oil pump chain and oil pump driven sprocket as a single unit.

Oil pump chain installation note

1.  Verify that the key and knock pin are aligned to the positions shown in the figure.

ac5uuw00009342

2.  Align the oil pump chain alignment marks with the oil pump driven sprocket alignment marks.

ac5wzw00008954

3.  Install the oil pump chain and oil pump driven sprocket as a single unit while aligning the alignment marks on each sprocket and oil pump chain as shown in the figure.

ac8wzw00003212

4.  Temporarily tighten the oil pump driven sprocket installation bolt.

5.  Install the oil pump chain tensioner No.1.

Caution

•  At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.

6.  Install the oil pump chain tensioner No.2.

ac5uuw00009344

Caution

•  At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.

7.  Tighten the oil pump driven sprocket installation bolt using the following procedure:

(1)  Lock the oil pump driven sprocket against rotation using the SST.

ac8jjw00000508

(2)  Tighten the oil pump driven sprocket installation bolt.

Tightening torque

123—140 N·m {13—14 kgf·m, 91—103 ft·lbf}

8.  Remove the wire or paper clip installed to the oil pump chain tensioner and apply tension to the oil pump chain.

•  If a new oil pump chain tensioner is used, remove the installed stopper.

Timing chain installation note

1.  Verify that the timing marks and the key are aligned to the position shown in the figure.

ac5wzw00005568

2.  Align the timing chain alignment mark with the crankshaft sprocket alignment mark.

ac5wzw00008957

Note

•  There are two timing chain alignment marks as shown in the figure. When assembling the timing chain and crankshaft sprocket, either timing chain alignment mark can be used.

ac5wzw00008958

3.  Install the timing chain and crankshaft sprocket as a single unit while aligning the marks on each sprocket and the timing chain as shown in the figure.

ac5wzw00008959

4.  Install the timing chain guide.

5.  Install the timing chain tensioner arm.

6.  Install the timing chain tensioner.

7.  After installing the timing chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing chain.

•  If a new chain tensioner is used, remove the installed stopper.

ac5wzw00005996

8.  Verify that there is no looseness in the timing chain, and re-verify that each sprocket is in the specified location.

9.  Rotate the crankshaft clockwise two turns and inspect the valve timing.

ac5wzw00005990

Engine front cover installation note

Note

•  For a new engine front cover, the positioning pins in the two locations shown in the figure project to the outside of the engine.

ac5wzw00005997

1.  If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.

ac5wzw00005998

Caution

•  If a bolt with silicone sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.

ac5wzw00005999

2.  When reusing an engine front cover installation bolts, remove silicone sealant adhering to the bolts.

Caution

•  If oil, dirt and silicone sealant remains on the silicone sealant application area, the silicone sealant will not seal which will cause oil leakage.

3.  Completely clean and remove any oil, dirt, silicone sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.

Caution

•  Apply the silicone 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.

4.  Apply silicone sealant (TB1217D or equivalent) to the engine front cover as shown in the figure.

ac8wzw00003213

Caution

•  Apply the silicone sealant so that it goes into the cylinder head gasket.

5.  Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

ac5wzw00006001

6.  Install the engine front cover to the engine.

Caution

•  For the number 1 and 8 bolts of the tightening order, install the bolts with new washers.

7.  Tighten the engine front cover installation bolts in the order shown in the figure.

ac5wzw00006609

Note

•  Install stud bolts because there are no stud bolts installed on a new engine front cover.

•  If the engine front cover is reused, tighten the stud bolts because they may have loosened.

8.  Tighten the engine front cover stud bolts.

ac5wzw00006004

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.

ac8wzw00002508

2.  Connect the connectors and clips shown in the figure and install the wiring harness and wiring harness bracket.

ac8wzw00002507

•  Connector A: Engine oil solenoid valve connector

•  Connector B: CKP sensor connector

Note

•  The seal rubber (No.3) can be fixed by installing the wiring harness bracket.

3.  Connect the connectors shown in the figure.

ac8wzw00002506

•  Connector A: Exhaust gas temperature sensor No.2 connector

•  Connector B: A/F sensor connector

•  Connector C: Exhaust gas temperature sensor No.3 connector

4.  Tighten the water pipe installation bolt.

ac8wzw00002505

Caution

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

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

ac5uuw00008440

No.3 engine mount installation note

Caution

•  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. When installing the No.3 engine mount, align the alignment mark placed during removal and install it to the original position.

Note

•  When replacing the No.3 engine mount, place a mark at the same position as the one placed before removal.

1.  Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:

(1)  Align the alignment marks on the body side and No.3 engine mount, and temporarily tighten the bolts shown in the figure.

ac5wzw00009373

(2)  Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 engine mount and nuts.

•  If the alignment marks are deviated, align the alignment marks while slightly moving the engine and temporarily tighten the nuts.

ac5wzw00009374

2.  Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.

ac5wzw00009375

3.  Remove the SST.

4.  Install the following parts.

(1)  Cowl panel (See COWL PANEL REMOVAL/INSTALLATION.)

(2)  Windshield wiper motor and link (See WINDSHIELD WIPER MOTOR AND LINK REMOVAL/INSTALLATION.)

(3)  Cowl grille (See COWL GRILLE REMOVAL/INSTALLATION.)

(4)  Windshield wiper arm and blade (See WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.)

5.  Install the wiring harness bracket.

ac8wzw00002504

6.  Install the PCM component using the following procedure:

(1)  Install the wiring harness protector.

ac8wzw00002509

Tightening torque

9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

(2)  Temporarily tighten the bolt shown in the figure.

ac8wzw00002510

(3)  Tighten the PCM component installation bolts in the order shown in the figure.

ac8wzw00002511

Tightening torque

9—10 N·m {92—101 kgf·cm, 80—88 in·lbf}

7.  Connect the active bonnet actuator connector (RH). (See ACTIVE BONNET ACTUATOR REMOVAL/INSTALLATION.)

8.  Install the ground cable to the PCM bracket.

ac8wzw00002502

Oil shower pipe installation note

1.  Install the oil shower pipe in the order shown in the figure.

ac5uuw00008441

Cylinder head cover installation note

Caution

•  To assure the sealing performance of the cylinder head cover, be careful of the following:

―  Verify that the cylinder head cover gasket is inserted into the cylinder head cover groove and install the cylinder head cover.

―  Completely clean and remove any oil, dirt, silicone sealant or other foreign matter from the seal surface.

1.  Install the oil seal on the cylinder head cover.

•  Verify if the oil seal shown in the figure has been damaged and if so replace it.

ac8wzw00002512

2.  Insert a new cylinder head cover gasket into the cylinder head cover groove.

Caution

•  To prevent silicone sealant from hardening, adhere the cylinder head cover and the cylinder head firmly within 10 min. after applying silicone sealant. After adhering them, tighten the installation bolts immediately.

3.  Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

Engine front side

ac5wzw00006610

Engine rear side

ac8wzw00002513

4.  Install the cylinder head cover.

5.  Tighten the cylinder head cover installation bolts using the following procedure:

(1)  Temporarily tighten the two bolts shown in the figure.

ac8wzw00002514

(2)  Tighten installation bolts A in the order shown in the figure.

aaxjjw00017854

Tightening torque

6.0—8.0 N·m {62—81 kgf·cm, 54—70 in·lbf}

(3)  Tighten installation bolts B in the order shown in the figure.

aaxjjw00017855

Tightening torque

4.5—7.0 N·m {46—71 kgf·cm, 40—61 in·lbf}

6.  Install the lower case and fuel hose bracket using the following procedure:

(1)  Return the lower case and the fuel hose bracket to their original positions.

(2)  Tighten the bolts and nut shown in the figure.

ac5uuw00008446

(3)  Install the wiring harness protector to the fuel hose bracket.

ac8wzw00002501

(4)  Install a new fuel return hose No.4. (See COMMON RAIL REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

(5)  Connect the vacuum hose to the vacuum pump.

7.  Install the exhaust gas temperature sensor No.1 bracket.

ac8wzw00002500

8.  Connect the wiring harness and ground cable using the following procedure:

(1)  Install the clips shown in the figure.

ac8wzw00002499

ac5wzw00009353

(2)  Connect the connectors and clip shown in the figure.

ac8wzw00002498

(3)  Tighten the nuts shown in the figure.

ac5uuw00008430

Tightening torque

9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

(4)  Install the adapter shown in the figure.

ac5uuw00008429

Tightening torque

4.0—5.6 N·m {41—57 kgf·cm, 36—49 in·lbf}

9.  Install the injection pipe (supply pump side). (See INJECTION PIPE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

10.  Install the fuel feed pipe. (See SUPPLY PUMP REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)