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Engine Disassembly/Assembly: Notes

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.
  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 

    Fig 1: Identifying Engine Clip
    G09758294Courtesy of MAZDA MOTORS CORP.
    Fig 2: Installing SST To Intake Manifold
    G09758295Courtesy of MAZDA MOTORS CORP.

    Engine rear side 

    Tightening torque 

    38-51 N.m {3.9-5.2 kgf.m, 29-37 ft.lbf} 

    Fig 3: Removing Vacuum Pipe Bolt
    G09758296Courtesy of MAZDA MOTORS CORP.
  3. Engage the hooks of the SST (49 L017 SA0)  to the SST (49 UN30 3050)  .
    Fig 4: Engaging Hooks Of SST (49 L017 SA0) To SST (49 UN30 3050)
    G09758297Courtesy of MAZDA MOTORS CORP.
  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.
    Fig 5: Caution - Do Not Lift Up Engine
    G09758298Courtesy of MAZDA MOTORS CORP.
  5. Remove the insulator shown in the figure.
  6. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  7. Remove the bolts in the order shown in the figure, then remove the exhaust manifold bracket.
    Fig 6: Removing Insulator Bolt With Torque Specification
    G09758299Courtesy of MAZDA MOTORS CORP.

    MTX 

    Fig 7: Removing Exhaust Manifold Bracket Bolts With Torque Specification (MTX)
    G09758300Courtesy of MAZDA MOTORS CORP.

    ATX 

    • When installing, tighten the bolts in the reverse order of removal.

    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. (AWD) (See TRANSFER REMOVAL/INSTALLATION .)
    Fig 8: Removing Exhaust Manifold Bracket Bolts With Torque Specification (ATX)
    G09758301Courtesy of MAZDA MOTORS CORP.
  10. Remove the starter. (See STARTER REMOVAL/INSTALLATION .)
  11. Fix the drive plate using the crankshaft pulley lock bolt. (ATX)
  12. Remove the torque converter installation nut from the starter installation hole. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6A-EL] (2WD).) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6AX-EL] (AWD).)
  13. Disconnect the engine and transaxle, and lower only the engine from the engine lifter. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION (MTX).) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6A-EL] (ATX, 2WD).) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6AX-EL] (ATX, AWD).)
  14. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5] .)
  15. Remove the intake-air system, (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  16. Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION .)
  17. Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION .)
  18. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION .)
  19. Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION .)
  20. Remove the oil filter. (See OIL FILTER REPLACEMENT .)
  21. Remove the oil cooler, (if equipped) (See OIL COOLER REMOVAL/INSTALLATION .)
  22. Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION .)
  23. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION .)
  24. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION .)
  25. Remove the wiring harness bracket shown in the figure.
  26. Remove the emission harness.
  27. Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  28. Remove the clutch cover and clutch disc. (MTX) (See CLUTCH UNIT REMOVAL/INSTALLATION .)
  29. Remove in the order indicated in the table
    Fig 9: Removing Wiring Harness Bracket Bolt With Torque Specification
    G09758302Courtesy of MAZDA MOTORS CORP.
  30. Assemble in the reverse order of disassembly.
    Fig 10: Oil Cooler Water Pipe Replacement Components With Torque Specifications
    G09758303Courtesy of MAZDA MOTORS CORP.
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