ENGINE DISASSEMBLY/ASSEMBLY [SKYACTIV-G 2.5]

id0110s6800500

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

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 to install the SST, disconnect the clip shown in the figure and set the wiring harness aside.

ac5uuw00006887

2.  Install the SST using part number 99794 1025 or an M10 x 1.25, length 25 mm {0.98 in} bolt as shown in the figure.

Engine front side

am6zzw00011712

Engine rear side

ac5uuw00006888

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

ac5uuw00006889

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

Caution

•  Do not lift up the engine.

ac5uuw00006890

5.  Remove the insulator shown in the figure.

ac5uuw00006891

6.  Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

7.  Remove the exhaust manifold bracket using the following procedure:

(1)  Loosen the bolt shown in the figure.

ac5uuw00006893

(2)  Remove the bolts in the order shown in the figure, then remove the exhaust manifold bracket.

ac5uuw00006895

•  When installing, install the exhaust manifold bracket using the following procedure:

1)  Temporarily tighten the exhaust manifold bracket installation bolts in the order as shown in the figure.

ac5uuw00006897

2)  Loosen the bolt shown in the figure until it is no longer seated on the surface.

ac5uuw00006893

3)  Tighten the bolt in the order shown in the figure.

ac5uuw00006899

Tightening torque

38—51 N·m {3.9—5.2 kgf·m, 29—37 ft·lbf}

8.  Remove the bracket No.1 (drive shaft bracket). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

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

10.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

11.  Remove the coolant control valve. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

12.  Fix the drive plate using the crankshaft pulley lock bolt.

13.  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).)

14.  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).)

15.  Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

16.  Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

17.  Remove the oil separator. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

18.  Remove the knock sensor (KS). (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

19.  Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

20.  Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

21.  Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

22.  Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

23.  Remove the electric variable valve timing motor/driver. (See ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

24.  Remove the oil filter. (See OIL FILTER REPLACEMENT [SKYACTIV-G 2.5].)

25.  Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

26.  Remove the engine oil temperature sensor/engine oil pressure sensor. (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

27.  Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

28.  Remove the dipstick.

29.  Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

30.  Remove the wiring harness bracket shown in the figure.

ac8wzw00003745

31.  Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

32.  Remove the Water inlet pipe and flange component. (See CYLINDER HEAD GASKET REPLACEMENT [SKYACTIV-G 2.5].)

33.  Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

34.  Remove the short cord of the engine oil level sensor. (See ENGINE OIL LEVEL SENSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].)

35.  Remove in the order indicated in the table.

36.  Assemble in the reverse order of disassembly.

ac8wzw00003746

1	Oil filter body (See Oil Filter Body Removal Note.) (See Oil Filter Body Installation Note.)
2	Exhaust manifold bracket (2WD) (See Exhaust Manifold Bracket Installation Note.)

Oil Filter Body Removal Note

1.  Remove the emission wiring harness using the following procedure.

(1)  Remove the bolts shown in the figure.

ac5wzw00012245

(2)  Remove all of the related wiring harness clip.

(3)  Remove the emission wiring harness.

2.  Remove the oil filter body.

Exhaust Manifold Bracket Installation Note

1.  Temporarily tighten the bolt (1) shown in the figure.

ac5uuw00006901

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

3.  Temporarily tighten the bolt (3) shown in the figure.

4.  Tighten the bolt in the order shown in the figure.

Oil Filter Body Installation Note

Note

•  The tightening order of the three bolts is optional.

1.  After tightening the three bolts, tighten the first tightened bolt to the specified tightening torque again.

2.  Install the emission wiring harness using the following procedure.

(1)  Return the emission wiring harness to their original position.

(2)  Tighten the bolts shown in the figure.

ac5wzw00012245

Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

(3)  Install all of the related wiring harness clip.