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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 Positioning Pin
G10951469Courtesy of MAZDA MOTORS CORP.
  1. If the engine front cover is newly replaced, tap the positioning pins in the two locations  to the seal surface side.
    Fig 2: Tapping Positioning Pins
    G10951470Courtesy of MAZDA MOTORS CORP.
  2. When reusing an engine front cover installation bolts, remove silicone sealant adhering to the bolts.
    CAUTION:
    • If a bolt with silicone sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.
    Fig 3: Caution - Silicone Sealant Removal
    G10951471Courtesy of MAZDA MOTORS CORP.
  3. Completely clean and remove oil, dirt, silicone sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.
    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.
    • 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.
  4. Apply silicone sealant (TB1217D or equivalent) to the engine front cover as shown in the figure.
    Fig 4: Identifying Sealant Bead Thickness
    G10951472Courtesy of MAZDA MOTORS CORP.

    Bead thickness 

    • A: 2-6 mm {0.1-0.2 in}
    • B: 4-6 mm {0.16-0.23 in}
    • C: 4-8 mm {0.2-0.3 in}
    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.
    Fig 5: Identifying Sealant Application Area
    G10951473Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Do not apply engine coolant to the O-ring (1). Otherwise, the O-ring could swell causing a seal malfunction.
      Fig 6: Caution - O-Ring Sealant Application
      G10951474Courtesy of MAZDA MOTORS CORP.
    • Do not apply oil (such as engine oil, ATF) to the O-ring (2). Otherwise, the O-ring could swell causing a seal malfunction.
  6. Install a new O-ring to the O-ring installation groove of the engine front cover.
  7. 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 7: Identifying Drive Belt Auto Tensioner Installation Bolt Hole
    G10951475Courtesy of MAZDA MOTORS CORP.
  8. Prepare an appropriate M8 x 1.25  bolt (length 40 mm {1.6 in}). 
    CAUTION:
    • For the number 3 bolt of the tightening order, install the bolt with new washer.
  9. Tighten the engine front cover installation bolts in the order shown in the figure.
    Fig 8: Engine Front Cover Bolt Tightening Sequence
    G10951476Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    • 20-26 N.m {2.1-2.6 kgf.m, 15-19 ft.lbf}
  10. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.
  11. Return the engine wiring harness to its original position using the following procedure.
    1. Connect or install the following parts.
      Fig 9: Identifying Engine Harness Parts With Torque Specifications
      G10951477Courtesy of MAZDA MOTORS CORP.
      COMPONENT DESCRIPTION

      1 Bolt
      2 Wiring harness clip
      3 Wiring harness clip
      4 Crankshaft position (CKP) sensor connector
      5 Engine oil solenoid valve connector
      6 A/F sensor connector
      7 Oil pressure switch connector
      Fig 10: Identifying Wiring Harness Clip And Wiring Harness Protector Installation Nut With Torque Specification
      G10951478Courtesy of MAZDA MOTORS CORP.
      COMPONENT DESCRIPTION

      1 IWiring harness clip
      2 IWiring harness clip
      3 Wiring harness installation nut
    2. Install the throttle body. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
    3. Connect or install the following parts.
      Fig 11: Identifying Throttle Body Components With Torque Specification
      G10951479Courtesy of MAZDA MOTORS CORP.
      COMPONENT DESCRIPTION

      1 iioh pressure fuel pump connector
      2 Exhaust camshaft position sensor connector
      3 Intake camshaft position sensor connector
      4 Wiring harness clip
      5 Bolt
    4. Connect the purge solenoid valve connector. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
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