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.

Fig 1: Identifying Engine Front Cover

Courtesy of MAZDA MOTORS CORP.

If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.
Completely clean and remove oil, dirt, sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.
When reusing an engine front cover installation bolts, remove sealant adhering to the bolts.
CAUTION:
- Apply the silicon 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.
  
  Fig 2: Removing Sealant Adhering To Bolts
  Courtesy of MAZDA MOTORS CORP.
- If a bolt with sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.
Apply silicone sealant to the engine front cover as shown in the figure.

Fig 3: Identifying Damage Bolt
Courtesy of MAZDA MOTORS CORP.

SKYACTIV-G 2.0

Fig 4: Identifying Engine Front Cover Silicone Sealant Applying Area (SKYACTIV-G 2.0)
Courtesy of MAZDA MOTORS CORP.

SKYACTIV-G 2.5

Fig 5: Identifying Engine Front Cover Silicone Sealant Applying Area (SKYACTIV-G 2.5)
Courtesy of MAZDA MOTORS CORP.

Bead thickness
1. 2-6 mm {0.1-0.2 in}
2. 4-6 mm {0.16-0.23 in}
3. 4-8 mm {0.2-0.3 in}
Apply silicone sealant to the areas shown in the figure.
CAUTION:
- Apply the silicone sealant so that it goes into the cylinder head gasket.
Install the engine front cover to the engine.
NOTE:
- Temporarily install an appropriate bolt to the drive belt auto tensioner installation bolt hole to prevent:
  - A silicone sealant adhesion malfunction in the drive belt auto tensioner installation bolt hole.
  - A bolt mis-installation due to silicone sealant hardening.
Fig 6: Identifying Cylinder Head Gasket Silicone Sealant Applying Area
Courtesy of MAZDA MOTORS CORP.
Prepare an appropriate M8 x 1.25 bolt (length 40 mm {1.6 in} ).
CAUTION:
- For the number 10 bolt of the tightening order, install the bolt with new washer.
Fig 7: Identifying Drive Belt Auto Tensioner Bolt Hole
Courtesy of MAZDA MOTORS CORP.
Tighten the engine front cover installation bolts in the order shown in the figure.

Fig 8: Engine Front Cover Installation Bolts Tightening Sequence
Courtesy of MAZDA MOTORS CORP.

Tightening torque

20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf}
Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.
Install the ground cable and wiring harness bracket shown in the figure.

Fig 9: Installing Ground Cable And Wiring Harness Bracket Bolts With Torque Specifications
Courtesy of MAZDA MOTORS CORP.
Install the insulator shown in the figure.

Fig 10: Insulator With Torque Specification
Courtesy of MAZDA MOTORS CORP.
Install the cooler hose (LO).

Fig 11: Cooler Hose And Nut With Torque Specifications
Courtesy of MAZDA MOTORS CORP.