Mazda SKYACTIV-G 2.5 Workshop Manual
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Mazda SKYACTIV-G 2.5 Workshop Manual

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Engine
Workshop
Manual
SKYACTIV-G 2.5
FOREWORD
This manual explains the service points for
the above-indicated automotive system.
This manual covers all models with the
above-indicated automotive system, not any
one specific model.
In order to do these procedures safely,
quickly, and correctly, you must first read
this manual and any other relevant service
materials carefully.
All the contents of this manual, including
drawings and specifications, are the latest
available at the time of printing.
As modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Mazda dealers. This manual
should be kept up-to-date.
Mazda Motor Corporation reserves the right
to alter the specifications and contents of
this manual without obligation or advance
notice.
All rights reserved. No part of this book may
be reproduced or used in any form or by any
means, electronic or mechanical—including
photocopying and recording and the use of
any kind of information storage and retrieval
system—without permission in writing.
Mazda Motor Corporation
HIROSHIMA, JAPAN
CONTENTS
GENERAL INFORMATION
ENGINE
© 2012 Mazda Motor Corporation
PRINTED IN U.S.A., DECEMBER 2012
Form No. 1A36–1U–12L
Part No. 9999–95–EWPY–14
Title
Section
00
01

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Summary of Contents for Mazda SKYACTIV-G 2.5

  • Page 1 As modifications affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice.
  • Page 3 The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

  • Page 4: Table Of Contents

    GENERAL INFORMATION SECTION 00-00 Toc of SCT GENERAL INFORMATION ..00-00 Toc of SCT 00-00 GENERAL INFORMATION HOW TO USE THIS MANUAL ..00-00–1 Preparation of Tools and Measuring Range of Topics .

  • Page 5: Service Procedure

    GENERAL INFORMATION Service Procedure Inspection, adjustment • Inspection and adjustment procedures are divided into steps. Important points regarding the SHOWS PROCEDURE ORDER location and contents of the procedures are FOR SERVICE explained in detail and shown in the illustrations. Fluid Pressure Inspection 1.
  • Page 6 GENERAL INFORMATION SHOWS SERVICE Procedure ITEM (S) INDICATES ANY RELEVANT REFERENCES WHICH NEED LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION 1. Jack up the rear of the vehicle and support it with safety stands. TO BE FOLLOWED DURING 00-00 "Removal/Installation" 2.

  • Page 7: Symbols

    GENERAL INFORMATION Symbols • There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols show application points or use of these materials during service. Symbol Meaning Kind Apply oil New appropriate engine oil or gear oil Apply brake fluid New appropriate brake fluid BRAKE...

  • Page 8: Units

    GENERAL INFORMATION UNITS id000000100400 Electric current A (ampere) Electric power W (watt) Electric resistance 00-00 Electric voltage V (volt) mm (millimeter) Length in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) Positive pressure kgf/cm (kilogram force per square centimeter)

  • Page 9: Abbreviations

    GENERAL INFORMATION ABBREVIATIONS id000000010100 Automatic Transaxle Exhaust Hydraulic Lash Adjuster Intake Manual Transaxle Oil Control Valve Top Dead Center Special Service Tool End Of Sie FUNDAMENTAL PROCEDURES GAIHAN: - id000000750100 Preparation of Tools and Measuring Equipment • Be sure that all necessary tools and measuring equipment are available before starting any work.

  • Page 10: Inspection During Removal, Disassembly

    GENERAL INFORMATION Inspection During Removal, Disassembly • When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems. 00-00 bpe2ue00000113 Arrangement of Parts • All disassembled parts should be carefully arranged for reassembly. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

  • Page 11: Adjustment

    • Depending on location: — Sealant and gaskets, or both, should be applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage. — Oil should be applied to the moving components of parts. —...

  • Page 12: Vise

    GENERAL INFORMATION Vise • When using a vise, put protective plates in the jaws of the vise to prevent damage to parts. End Of Sie 00-00 PROTECTIVE PLATES bpe2ue00000120 00-00–9...
  • Page 14 ENGINE SECTION 01-10 Toc of SCT MECHANICAL....01-10 SERVICE TOOLS ... 01-60 TECHNICAL DATA ..01-50 Toc of SCT 01-10 MECHANICAL...

  • Page 15: Mechanical

    MECHANICAL Piston Pin Assembly Note... 01-10–44 Thermostat Assembly Note ..01-10–58 Snap Ring Assembly Note ..01-10–44 CYLINDER HEAD ASSEMBLY (II) .

  • Page 16: Hydraulic Variable Valve Timing Actuator Inspection

    MECHANICAL HYDRAULIC VARIABLE VALVE TIMING ACTUATOR INSPECTION id011000126800 Caution • Do not disassemble the hydraulic variable valve timing actuator because it is a precision unit. 1. Verify that the notch of the rotor and projection of PROJECTION the cover on the hydraulic variable valve timing 01-10 actuator are aligned and fitted.

  • Page 17: Oil Control Valve (Ocv) Inspection

    MECHANICAL OIL CONTROL VALVE (OCV) INSPECTION id011000801400 Coil Resistance Inspection 1. Measure the resistance between terminals A and B using an ohmmeter. OIL CONTROL VALVE (OCV) OCV coil resistance 6.9—7.5 ohms [20°C {68°F}] • If it is not within the specification, replace the OCV.

  • Page 18: Hydraulic Lash Adjuster (Hla) Inspection

    MECHANICAL HYDRAULIC LASH ADJUSTER (HLA) INSPECTION id011000805000 1. Visually inspect the HLA surface where it contacts the rocker arm for wear or damage. ROCKER ARM • If there is any malfunction, replace the HLA. CONTACT SURFACE End Of Sie WM: ROCKER ARM 01-10 am3uuw00008989 ROCKER ARM INSPECTION...

  • Page 19: Engine Mounting/Dismounting

    MECHANICAL ENGINE MOUNTING/DISMOUNTING id011000507000 Mounting 1. Install the SST (arms) to the three positions as shown in the figure and temporarily tighten the bolts (Part No. 9YA20-1003 or M10 × 1.5 length 90 mm {3.55 in}). SST INSTALLATION HOLE SST INSTALLED 49 L010 102 ENGINE FRONT bpe1ze00000084...

  • Page 20: Timing Chain Disassembly

    MECHANICAL TIMING CHAIN DISASSEMBLY id011000505500 Caution • If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.
  • Page 21 MECHANICAL 1. Disassemble in the order indicated in the table. bpe1ze00000062 Dipstick Spark plug Cylinder head cover Water pump pulley (See 01-10-9 Water Pump Pulley Disassembly Note.) Oil shower pipe 01-10–8...

  • Page 22: Water Pump Pulley Disassembly Note

    MECHANICAL Crankshaft pulley lock bolt 15 Timing chain (See 01-10-10 Crankshaft Pulley Lock Bolt 16 Chain guide (No.2) Disassembly Note.) 17 Crankshaft sprocket Crankshaft pulley 18 Oil pump chain tensioner Electric variable valve timing motor/driver (See 01-10-12 Oil Pump Chain Disassembly Note.) Oil pan 19 Balancer shaft sprocket (See 01-10-10 Oil Pan Disassembly Note.)

  • Page 23: Crankshaft Pulley Lock Bolt Disassembly Note

    MECHANICAL Crankshaft Pulley Lock Bolt Disassembly Note 1. Hold the crankshaft using the SST. 2. Remove the crankshaft pulley lock bolt. 49 E011 1A0 bpe1ze00000063 Oil Pan Disassembly Note 1. Remove the oil pan using a separator tool. adejjw00003946 Engine Front Cover Disassembly Note 1.

  • Page 24: Front Oil Seal Disassembly Note

    MECHANICAL Front Oil Seal Disassembly Note 1. Remove the oil seal using a flathead screwdriver with the tip protected by a clean cloth. CLOTH 01-10 FRONT OIL SEAL bpe2ue00000100 Chain Tensioner Disassembly Note 1. While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision...

  • Page 25: Oil Pump Chain Disassembly Note

    MECHANICAL 5. Insert a wire with an approx. diameter of 1.5 mm {0.059 in} or a paper clip where the link plate hole and the tensioner body hole overlap to secure the link plate and lock the plunger. 6. Remove the chain tensioner. WIRE OR PAPER CLIP LINK PLATE...
  • Page 26 MECHANICAL 4. Move the screwdriver in the direction of the arrow and press the oil pump chain, and then press on the plunger of the oil pump chain tensioner. OIL PUMP CHAIN OIL PUMP DRIVE SPROCKET 01-10 OIL PUMP CHAIN TENSIONER BEFORE PRESSING AFTER PRESSING PLUNGER...

  • Page 27: Cylinder Head Disassembly (I)

    MECHANICAL CYLINDER HEAD DISASSEMBLY (I) id011000500400 Caution • If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.
  • Page 28 MECHANICAL 1. Disassemble in the order indicated in the table. 01-10 WITHOUT OIL COOLER WATER PUMP WITH OIL COOLER bpe5ue00000001 Electric variable valve timing actuator, hydraulic OCV oil filter variable valve timing actuator Rocker arm (See 01-10-16 Electric Variable Valve Timing (See 01-10-16 Rocker Arm Disassembly Note.) Actuator, Hydraulic Variable Valve Timing Actuator Disassembly Note.)

  • Page 29: Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Disassembly Note

    MECHANICAL Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Disassembly Note 1. Hold the camshaft using a wrench on the cast hexagon and loosen the actuator installation bolt. bp31je00000161 Camshaft Cap Disassembly Note 1. Before removing the camshaft cap, Inspect the camshaft end play. (See 01-10-30 CAMSHAFT INSPECTION.) 2.

  • Page 30: Cylinder Head Disassembly (Ii)

    MECHANICAL CYLINDER HEAD DISASSEMBLY (II) id011000500500 1. Disassemble in the order indicated in the table. 01-10 bpe1ze00000013 Thermostat cover Valve spring Thermostat Valve Water outlet Valve seal (See 01-10-18 Valve Seal Disassembly Note.) Valve keeper (See 01-10-18 Valve Keeper Disassembly Note.) Lower valve spring seat Upper valve spring seat 01-10–17...

  • Page 31: Valve Keeper Disassembly Note

    MECHANICAL Valve Keeper Disassembly Note 1. Remove the valve keeper using the SSTs. 49 B012 0A2A 49 0636 100B bpe1ze00000014 Valve Seal Disassembly Note 1. Remove the valve seal using the SST or pliers. 49 S120 170 VALVE SEAL VALVE GUIDE bpe1ze00000015 End Of Sie VALVE SEAL...

  • Page 32: Cylinder Block Disassembly (I)

    MECHANICAL CYLINDER BLOCK DISASSEMBLY (I) id011000500600 Caution • Do not disassemble the oil pump, water pump and balancer unit because it is a precision unit. 1. Disassemble in the order indicated in the table. 01-10 bpe5ue00000002 Knock sensor (KS) End plate Oil separator Rear oil seal (See 01-10-21 Rear Oil Seal Disassembly Note.)

  • Page 33: Dual-Mass Flywheel (Mtx)/ Drive Plate (Atx) Installation Bolt Disassembly Note

    MECHANICAL Dual-mass Flywheel (MTX)/ Drive Plate (ATX) Installation Bolt Disassembly Note Dual-mass flywheel installation bolt (MTX) 1. Hold the crankshaft using the SST (49 E011 1A0). 2. Loosen the bolts uniformly and gradually in the order shown in the figure. Note •...

  • Page 34: Dual-Mass Flywheel Disassembly Note (Mtx)

    MECHANICAL Dual-mass Flywheel Disassembly Note (MTX) Note • When reusing the dual-mass flywheel, do not remove the SST (49 G033 102) locking the dual-mass flywheel (secondary flywheel side) against rotation. Rear Oil Seal Disassembly Note 1. Cut the oil seal lip using a utility knife. 01-10 2.

  • Page 35: Cylinder Block Disassembly (Ii)

    MECHANICAL CYLINDER BLOCK DISASSEMBLY (II) id011000500700 1. Disassemble in the order indicated in the table. bpe1ze00000038 Pilot bearing (MTX) Piston ring (See 01-10-23 Pilot Bearing Disassembly Note.) Snap ring Connecting rod cap (See 01-10-24 Snap Ring Disassembly Note.) (See 01-10-23 Connecting Rod Cap Disassembly Piston pin Note.) Piston...

  • Page 36: Pilot Bearing Disassembly Note

    MECHANICAL Crankshaft Thrust bearing (See 01-10-25 Crankshaft Disassembly Note.) (See 01-10-25 Thrust Bearing And Main Bearing Disassembly Note.) Plate Oil jet valve Upper main bearing (See 01-10-25 Thrust Bearing And Main Bearing Upper cylinder block Disassembly Note.) 01-10 Pilot Bearing Disassembly Note Note •...

  • Page 37: Snap Ring Disassembly Note

    MECHANICAL Snap Ring Disassembly Note 1. Before removing the snap ring, verify that the large end of connecting rod drops under its own weight with no resistance. (See 01-10-35 PISTON AND CONNECTING ROD INSPECTION.) 2. Remove the snap ring using a flathead screwdriver.

  • Page 38: Thrust Bearing And Main Bearing Disassembly Note

    MECHANICAL 4. Using a screwdriver wrapped in a cloth, peel the LOWER CYLINDER BLOCK sealant away a little at a time, and remove the lower cylinder block. Caution • Do not apply excessive force to the screwdriver. Otherwise, the lower cylinder block could be damaged.

  • Page 39: Valve Seat Inspection/Repair

    MECHANICAL 3. Inspect the contact surface of the exhaust manifold and the intake manifold for distortion by measuring as shown in the figure using a straight edge and feeler gauge. • If the distortion on the intake manifold side exceeds the maximum specification, replace the cylinder head.

  • Page 40: Valve, Valve Guide Inspection

    MECHANICAL 3. Inspect the valve seat for sinkage. Measure the protruding length (dimension L) of the valve stem using a valve of standard length. • If it is not within the specification, replace the cylinder head. Standard valve seat sinkage amount (Dimension L) 01-10 IN: 48.93—50.17 mm {1.927—1.975 in}...
  • Page 41 MECHANICAL 4. Measure the inner diameter of each valve guide using the caliper gauge. Measurement positions total six and are in the X and Y directions, at three points (A, B, and C) as shown in the figure. • If it is not within the specification, replace the valve guide.

  • Page 42: Valve Guide Replacement

    MECHANICAL VALVE GUIDE REPLACEMENT id011000501200 Removal 1. Tap the valve guide out from combustion chamber side using the SST. 49 B012 015 01-10 VALVE GUIDE bpe2ue00000026 Installation 1. Apply clean engine oil to the valve guide. 2. Tap the valve guide from the camshaft side using the SST so that the projection height (dimension 49 B012 015 A) is within the specification.

  • Page 43: Camshaft Inspection

    MECHANICAL 1. Measure the valve spring height using the spring tester. • If it is not within the specification, replace the valve spring. Valve spring installation height When pressurized with spring force of 228— 252 N {23.3—25.6 kgf, 51.3—56.6 lbf}, spring height is 38.0 mm {1.50 in} bp31je00000053 2.
  • Page 44 MECHANICAL 4. Measure the journal diameter using the micrometer. Measurement positions total four and are in the X and Y directions, at two points (A and B) as shown in the figure. • If it is less than the minimum specification, replace the camshaft.

  • Page 45: Cylinder Block Inspection

    MECHANICAL CYLINDER BLOCK INSPECTION id011000507200 1. Measure the cylinder block for distortion in six directions as shown in the figure using a straight edge and feeler gauge. • If it exceeds the maximum specification, replace the cylinder block. Maximum distortion, head gasket side of the cylinder block 0.10 mm {0.0039 in} bp31je00000144...

  • Page 46: Piston Ring Inspection

    MECHANICAL 3. Calculate the cylinder-to-piston clearance from the cylinder bore diameter and the piston outer diameter. • If the clearance exceeds the maximum specification, replace the piston or cylinder block. Standard clearance between piston and cylinder 0.025—0.045 mm {0.0010—0.0017 in} Maximum clearance between piston and cylinder 0.066 mm {0.0026 in} 01-10...

  • Page 47: Piston Pin Inspection

    MECHANICAL PISTON PIN INSPECTION id011000507500 Caution • If the piston or piston pin is replaced, replace the piston, piston pin and the snap ring as a single component. 1. Measure the piston pin outer diameter using the micrometer. Measurement positions total eight and are in the X and Y directions, at four points (A, B, C, and D) as shown in the figure.

  • Page 48: Piston And Connecting Rod Inspection

    MECHANICAL PISTON AND CONNECTING ROD INSPECTION id011000503100 1. Check the oscillation torque as shown in the figure. Verify that the large end drops under its own weight with no resistance. • If the piston shakes heavily or unsmoothly, disassemble the piston and connecting rod, then inspect the following: (See 01-10-34 01-10 PISTON PIN INSPECTION.)

  • Page 49: Crankshaft Inspection

    MECHANICAL Standard bearing oil clearance at the large end of the connecting rod 0.026—0.052 mm {0.0011—0.0020 in} Maximum bearing oil clearance at the large end of the connecting rod 0.10 mm {0.0039 in} Connecting rod bearing size STD: 1.502—1.519 mm {0.05914—0.05980 in} OS 0.25: 1.628—1.631 mm {0.06410—0.06421 in} OS 0.50: 1.753—1.756 mm {0.06902—0.06913 in} End Of Sie...

  • Page 50: Dual-Mass Flywheel Inspection

    MECHANICAL 4. Inspect the main journal oil clearance using the following procedure: (1) Install the thrust bearing, upper main bearing and crankshaft. (2) Position a plastigauge on the journals. (3) Install the lower main bearing and lower cylinder block. (See 01-10-40 CYLINDER BLOCK ASSEMBLY (I).) (4) Remove the lower cylinder block.

  • Page 51: Inspection After Removal

    MECHANICAL 3. Measure the amount of guide pin projection of the dual-mass flywheel. • If it exceeds the maximum amount, replace the dual-mass flywheel. Dual-mass flywheel guide pin projection maximum amount 11.0—12.0 mm {0.434—0.472 in} ac5wzw00005674 4. Using a dial indicator, measure the dual-mass flywheel runout.

  • Page 52: Pilot Bearing Inspection

    MECHANICAL PILOT BEARING INSPECTION id011000505200 1. Without removing the pilot bearing, turn the bearing while applying force in the axial direction. • If there is any malfunction, replace the pilot bearing. End Of Sie 01-10 am3uuw00002078 BOLT INSPECTION id011000503300 1. Measure the length of the each bolt. •...

  • Page 53: Cylinder Block Assembly (I)

    MECHANICAL CYLINDER BLOCK ASSEMBLY (I) id011000504000 1. Assemble in the order indicated in the table. 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} 20—26 {2.1—2.6, 15—19} 26—32 {2.7—3.2, 20—23} ° SEALANT SEALANT +80—100 38—42 {3.9—4.2, 29—30} LOOSEN ALL THE BOLTS (UNTIL BOLTS ARE TORQUE-FREE) 19—25 {2.0—2.5, +30—34 {3.1—3.4, 23—25}...

  • Page 54: Thrust Bearing And Main Bearing Assembly Note

    MECHANICAL Piston ring Lower connecting rod bearing (See 01-10-45 Piston Ring Assembly Note.) (See 01-10-46 Connecting Rod Bearing Assembly Note.) Upper connecting rod bearing (See 01-10-46 Connecting Rod Bearing Assembly Connecting rod cap Note.) (See 01-10-47 Connecting Rod Cap Assembly Note.) Piston, connecting rod (See 01-10-46 Piston, Connecting Rod Assembly...

  • Page 55: Plate Assembly Note

    MECHANICAL Plate Assembly Note Caution • Placing the crankshaft on a disassembly bench will deform or damage it because the plate for the crankshaft position sensor signal detection installed to the crankshaft is larger than the counterweight. Therefore, set wood blocks or similar objects on the both sides of the crankshaft so that the plate does not contact the disassembly bench directly when placing the crankshaft on it bench.
  • Page 56 MECHANICAL 3. Apply silicon sealant to the lower cylinder block shown in the figure. ENGINE FRONT 01-10 SEALANT SEALANT LESS THAN 4 mm {0.2 in} LOWER CYLINDER SEALANT SEALANT LESS THAN BLOCK 4 mm {0.2 in} SECTION A-A SEALANT SEALANT 0.5—1.5 mm {0.02—0.05 in} SEALANT...

  • Page 57: Piston Pin Assembly Note

    MECHANICAL (2) Tighten lower cylinder block installation bolts A in the order shown in the figure using the following procedure: Tightening procedure Step 1: 38—42 N·m {3.9—4.2 kgf·m, 29—30 ft·lbf} Step 2: Loosen all the bolts (until bolts are torque-free). Step 3: 30—34 N·m {3.1—3.4 kgf·m, 23—25 ENGINE ft·lbf}...

  • Page 58: Piston Ring Assembly Note

    MECHANICAL Piston Ring Assembly Note Note • It is not required to position the end gap between the top ring and second ring. 1. Assemble the oil ring so that the end gap of each 30° 30° oil ring rail does not overlap as shown in the figure.

  • Page 59: Connecting Rod Bearing Assembly Note

    MECHANICAL Connecting Rod Bearing Assembly Note Caution • If a connecting rod bearing is reused, assemble it to the same position and in the direction as before removal to prevent engine damage due to seizure or burning of the bearing. •...

  • Page 60: Connecting Rod Cap Assembly Note

    MECHANICAL Connecting Rod Cap Assembly Note Caution • When assembling the connecting rod caps, align the broken, rough faces of the connecting rods and connecting rod caps. • If the following condition is met, replace the connecting rod cap bolts. —...

  • Page 61: Cylinder Block Assembly (Ii)

    MECHANICAL CYLINDER BLOCK ASSEMBLY (II) id011000504100 1. Assemble in the order indicated in the table. 108—116 {11.1—11.8, 80—85} 152—160 {15.5—16.3, 113—118} 17—23 {1.8—2.3, 20—26 {2.1—2.6, 15—19} 13—16} 16—22 {1.7—2.2, 12—16} +30—36 {3.1—3.6, 23—26} 20—26 {2.1—2.6, 15—19} 20—26 {2.1—2.6, 15—19} *1: 8—11 N·m {82—112 kgf·m, 71—97 ft·lbf} N·m {kgf·m, ft·lbf} bpe5ue00000005 Balancer unit...

  • Page 62: Balancer Unit Assembly Note

    MECHANICAL Balancer Unit Assembly Note 1. Assemble the balancer unit using the following procedure: (1) Tighten the bolts in the order shown in the BALANCER UNIT figure. 01-10 ENGINE FRONT bpe1ze00000051 Tightening torque Installation position Tightening torque 1—4 16—22 N·m {1.7—2.2 kgf·m, 12—16 ft·lbf} 5, 6 20—26 N·m {2.1—2.6 kgf·m, 15—19 ft·lbf} (2) Retighten the bolts in the order of the...

  • Page 63: Oil Pump Assembly Note

    MECHANICAL Oil Pump Assembly Note 1. Install the oil pump using the following procedure: (1) Temporarily tighten the three bolts shown in the figure. BOLT OIL PUMP BOLT BOLT ENGINE FRONT bpe1ze00000053 (2) Tighten the two bolts shown in the figure to the specified torque.

  • Page 64: Water Pump Assembly Note

    MECHANICAL Water Pump Assembly Note Caution • Assemble the water pump gasket to the correct direction shown in the figure. Otherwise, it could leak engine coolant and damage the engine. WATER PUMP GASKET GROOVE WATER PUMP 01-10 bpe2ue00000053 1. Insert a new water pump gasket into the water pump groove. 2.

  • Page 65: Rear Oil Seal Assembly Note

    MECHANICAL Rear Oil Seal Assembly Note 1. Apply clean engine oil to the inner surface of a new rear oil seal. 2. Insert the rear oil seal into the cylinder block by hand. 3. Tap the oil seal in evenly using the SST and a hammer.

  • Page 66: End Plate Assembly Note

    MECHANICAL End Plate Assembly Note 1. After end plate assembly, crimp the parts A and B shown in the figure. END PLATE 10 {0.39} 01-10 10 {0.39} TUBULAR TUBULAR PIN 10 {0.39} mm {in} bpe2ue00000055 Crimp procedure Crimp depth: 0.1—1.0 mm {0.004—0.039 in} Crimp width: 0.5—10.0 mm {0.02—0.39 in} Crimp locations: Part A is 1 or more on one-side within shaded area and part B is 2 or more within shaded areas...

  • Page 67: Knock Sensor (Ks) Assembly Note

    MECHANICAL (2) Install the SST (49 S120 710) to the dual- 49 E011 1A0 mass flywheel. (3) Rotate the dual-mass flywheel (secondary flywheel side) using the SST (49 S120 710), and then temporarily tighten the remaining 49 G033 102 new bolt after removing the SST (49 G033 102).

  • Page 68: Cylinder Head Assembly (I)

    MECHANICAL CYLINDER HEAD ASSEMBLY (I) id011000504300 1. Assemble in the order indicated in the table. 01-10 8—11 {82—112, 71—97} N·m {kgf·cm, in·lbf} bpe1ze00000017 Lower valve spring seat Valve keeper (See 01-10-57 Valve Keeper Assembly Note.) Valve seal (See 01-10-56 Valve Seal Assembly Note.) Water outlet (See 01-10-57 Water Outlet Assembly Note.) Valve...

  • Page 69: Valve Seal Assembly Note

    MECHANICAL Valve Seal Assembly Note 1. Press on the valve seal to the valve guide using the SST by hand. Valve seal identification color 9.52 mm {0.375 in} IN: GREEN EX: GRAY 49 B012 016 3.5 mm {0.14 in} VALVE SEAL 49 B012 016 VALVE SEAL bpe1ze00000057...

  • Page 70: Valve Keeper Assembly Note

    MECHANICAL Valve Keeper Assembly Note 1. Install the valve keeper using the SST. 01-10 49 B012 0A2A 49 0636 100B bpe1ze00000020 Water Outlet Assembly Note 1. Install the water outlet gasket with the bead of the gasket facing the direction shown in the figure. 2.

  • Page 71: Thermostat Assembly Note

    MECHANICAL 3. Tighten bolt A of the 5 bolts shown in the figure to BOLT the specified torque first. Tightening torque 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} Note • The tightening order for the remaining 3 bolts is optional. BOLT bpe1ze00000022 Thermostat Assembly Note 1.

  • Page 72: Cylinder Head Assembly (Ii)

    MECHANICAL CYLINDER HEAD ASSEMBLY (II) id011000504400 Caution • If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.
  • Page 73 MECHANICAL 1. Assemble in the order indicated in the table. 8—11 N·m 3.0—6.0 N·m {82—112 kgf·cm, {31—61 kgf·cm, 71—97 in·lbf} 27—53 in·lbf} +8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} 75—85 {7.7—8.6, 56—62} 102—114 {10.5—11.6, 76—84} 12—16 N·m {123—163 kgf·cm, 107—141 in·lbf} WITHOUT OIL COOLER 13—17 N·m {133—173 kgf·cm,...

  • Page 74: Cylinder Head Assembly Note

    MECHANICAL Cylinder Head Assembly Note Caution • If the following condition is met, replace the cylinder head bolts. — Length exceeds maximum specification Standard cylinder head bolt length L 01-10 145.2—145.8 mm {5.717—5.740 in} Maximum cylinder head bolt length L 146.5 mm {5.767 in} 1.

  • Page 75: Water Inlet Pipe Assembly Note

    MECHANICAL Water Inlet Pipe Assembly Note Caution • Do not apply oil (such as engine oil, ATF) to the O-ring of the water inlet pipe. Otherwise, the O- ring could swell causing a seal malfunction. 1. Clean away the sealant adhering to the bolt hole on the cylinder block side of the water inlet pipe stay. 2.

  • Page 76: Hla Assembly Note

    MECHANICAL HLA Assembly Note 1. Perform HLA air bleeding using the following procedure: (1) Put the HLA in a container filled with engine oil. Caution • Do not insert the round bar firmly because the check ball spring force is extremely weak. (2) While lightly pressing the check ball using a 01-10 round bar (approx.

  • Page 77: Camshaft Assembly Note

    MECHANICAL Camshaft Assembly Note 1. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the cylinder head. Caution • Apply 0.05 ml {0.05 cc, 0.003 in } or less of oil to journal No.6.
  • Page 78 MECHANICAL 4. As shown in the figure, apply gear oil (SAE No. 90 or equivalent) or engine oil to the center area of each journal of the camshaft. 01-10 bpe1ze00000011 5. Apply adhesive agent (Loctite 962T) around journal No.6 of the cylinder head or the exhaust- CYLINDER HEAD side rear camshaft cap.

  • Page 79: Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Assembly Note

    MECHANICAL 7. Tighten the camshaft cap installation bolts in two steps in the order shown in the figure. MARKED NUMBER MARKED NUMBER am3uuw00008996 Tightening torque Step 1: 3.0—6.0 N·m {31—61 kgf·cm, 27—53 in·lbf} Step 2: 8—11 N·m {82—112 kgf·cm, 71—97 in·lbf} Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Assembly Note 1.

  • Page 80: Timing Chain Assembly

    MECHANICAL 2. Hold the camshaft using a wrench on the cast hexagon, and tighten the actuator installation bolt. Tightening torque Electric variable valve timing actuator (intake side): 102—114 N·m {10.5—11.6 kgf·m, 76—84 ft·lbf} Hydraulic variable valve timing actuator 01-10 (exhaust side): 75—85 N·m {7.7—8.6 kgf·m, 56—62 ft·lbf} End Of Sie bpe2ue00000073...
  • Page 81 MECHANICAL 1. Assemble in the order indicated in the table. 4.5—7.0 N·m {46—71 kgf·m, 40—61 ft·lbf} SEALANT SEALANT 8.0—9.0 N·m {82—91 kgf·m, 9—12 N·m 71—79 ft·lbf} {92—122 kgf·m, 80—106 ft·lbf} 20—26 {2.1—2.6, 15—19} 15—20 {1.6—2.0, 12—14} SEALANT SEALANT SEALANT SEALANT SEALANT SEALANT 90—110...

  • Page 82: Oil Pump Chain Assembly Note

    MECHANICAL Oil pump chain 15 Oil pan (See 01-10-69 Oil Pump Chain Assembly Note.) (See 01-10-77 Oil Pan Assembly Note.) Balancer shaft sprocket 16 Electric variable valve timing motor/driver (See 01-10-69 Oil Pump Chain Assembly Note.) (See 01-10-79 Electric Variable Valve Timing Motor/ Driver Assembly Note.) Oil pump chain tensioner (See 01-10-69 Oil Pump Chain Assembly Note.)
  • Page 83 MECHANICAL 5. Install the oil pump chain and balancer shaft sprocket as a single unit while aligning the alignment marks on each sprocket and oil pump chain as shown in the figure. OIL PUMP CHAIN ALIGNMENT MARK (YELLOW) OIL PUMP DRIVE SPROCKET ALIGNMENT MARK BALANCER SHAFT...

  • Page 84: Timing Chain Assembly Note

    Note • The timing mark of SKYACTIV-G 2.5 is not completely parallel with the upper surface of the cylinder head. • If they are not in the position shown in the figure, rotate the camshaft and crankshaft to set the cylinder No.1 top dead center (TDC).
  • Page 85 MECHANICAL 2. Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure. TIMING CHAIN ALIGNMENT MARK (ORANGE) CYLINDER HEAD UPPER SURFACE TIMING MARK HYDRAULIC VARIABLE VALVE TIMING ACTUATOR TIMING CHAIN ALIGNMENT MARK CRANKSHAFT SPROCKET TIMING CHAIN TIMING CHAIN...
  • Page 86 8. Rotate the crankshaft clockwise two turns and inspect the valve timing. CYLINDER 01-10 HEAD UPPER SURFACE TIMING MARK bpe5ue00000010 Note • The timing mark of SKYACTIV-G 2.5 is not completely parallel with the upper surface of the cylinder head. 01-10–73...

  • Page 87: Engine Front Cover Assembly Note

    MECHANICAL Engine Front Cover Assembly 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. VIEW FROM A ENGINE OUTSIDE POSITIONING SEAL SIDE POSITIONING PIN bpe1ze00000006 1.
  • Page 88 MECHANICAL 4. Apply silicone sealant to the engine front cover as shown in the figure. SEALANT SEALANT 01-10 10 {0.39} 10 {0.39} 10 {0.39} 10 {0.39} SECTION D-D 1.5 mm — {0.02 0.05 in} — SEALANT SEALANT ° 10 {0.39} ENGINE FRONT 32.5 {1.28} COVER...
  • Page 89 MECHANICAL 5. Apply silicone sealant to the areas shown in the figure. Caution • Apply the silicone sealant so that it goes into the cylinder head gasket. 6. Install the engine front cover to the engine. Note • Temporarily install an appropriate bolt to the VIEW FROM A drive belt auto tensioner installation bolt hole SEALANT...

  • Page 90: Oil Pan Assembly Note

    MECHANICAL 8. Tighten the engine front cover installation bolts in the order shown in the figure. 01-10 WASHER M8 x 1.25, LENGTH 40 mm {1.6 in} bpe1ze00000079 Tightening torque 20—26 N·m {2.1—2.6 kgf·cm, 15—19 in·lbf} 9. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.
  • Page 91 MECHANICAL 3. Apply silicone sealant to the oil pan along the inside of the bolt holes as shown in the figure. A-A SECTIONAL VIEW CYLINDER BLOCK SEALANT SEALANT 0.5—1.5 mm {0.02—0.05 in} SEALANT SEALANT OIL PAN bpe5ue00000011 Thickness 3.0—7.0 mm {0.12—0.27 in} 4.

  • Page 92: Electric Variable Valve Timing Motor/Driver Assembly Note

    MECHANICAL Electric Variable Valve Timing Motor/Driver Assembly Note 1. Install a new O-ring to the O-ring installation groove of the engine front cover. Caution • To prevent damage to the electric variable valve timing motor/driver, do not apply excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the shaded 01-10 areas shown in the figure.

  • Page 93: Front Oil Seal Assembly Note

    MECHANICAL Front Oil Seal Assembly Note 1. Apply clean engine oil to the inner surface of a new front oil seal. 2. Insert the front oil seal into the engine front cover by hand. 3. Tap the oil seal in evenly using the SST and a hammer.

  • Page 94: Water Pump Pulley Assembly Note

    MECHANICAL Water Pump Pulley Assembly Note Caution • Be careful not to damage the belt groove and surface of the water pump pulley when using tools, otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to the pulley, and rust.

  • Page 95: Cylinder Head Cover Assembly Note

    MECHANICAL Tightening torque Installation position Tightening torque 9—12 N·m {92—122 kgf·cm, 80—106 in·lbf} 2, 3 8.0—9.0 N·m {82—91 kgf·cm, 71—79 in·lbf} Cylinder Head Cover Assembly Note Caution • To assure the sealing performance of the cylinder head cover, be careful of the following: —...

  • Page 96: Tightening Torque

    MECHANICAL 2. Apply silicone sealant to the areas shown in the figure. ENGINE FRONT SIDE SEALANT SEALANT CYLINDER HEAD 01-10 VIEW FROM A 2—6 mm 4—5 mm 3—13 mm 3—13 mm {0.1—0.2 in} {0.16—0.19 in} {0.2—0.5 in} {0.2—0.5 in} ENGINE FRONT COVER SEALANT SEALANT ENGINE...
  • Page 98 TECHNICAL DATA 01-50 TECHNICAL DATA ENGINE TECHNICAL DATA ..01-50–1 End of Toc ENGINE TECHNICAL DATA WM: ENGINE id015000800100 01-50 Item Specification OCV coil resistance 6.9—7.5 ohms [20°C {68°F}] Maximum distortion, head gasket side of the cylinder 0.05 mm {0.002 in} head IN: 0.10 mm {0.0039 in}...
  • Page 99 TECHNICAL DATA Item Specification Top: 0.04—0.08 mm {0.002—0.003 in} Standard clearance between piston ring and ring Second: 0.03—0.07 mm {0.0012—0.0027 in} groove Oil: 0.04—0.12 mm {0.002—0.004 in} Top: 0.12 mm {0.0047 in} Maximum clearance between piston ring and ring Second: 0.10 mm {0.0039 in} groove Oil: 0.17 mm {0.0067 in} Top: 0.13—0.18 mm {0.0052—0.0070 in}...
  • Page 100 ENGINE SST ..... . 01-60–1 End of Toc ENGINE SST SOKYU_WM: ENGINE id016000119200 01-60 1: Mazda SST number 2: Global SST number Example 1: 49 E011 1A0 2: – Ring gear brake...

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