Engine Disassembly/Assembly: Notes

Special Service Tool (SST) 

1.: Mazda SST number 2.: Global SST number
1: 49 UN30 3050 2: 303-050 Engine lifting bracket	Courtesy of MAZDA MOTORS CORP.	1: 49 L017 5A0 2:- Support hanger	Courtesy of MAZDA MOTORS CORP.

Replacement Part 

Gasket

Quantity: 1

Location of use: Oil filter body

1. 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 

   Courtesy of MAZDA MOTORS CORP.

   Engine rear side 

   Courtesy of MAZDA MOTORS CORP.

   Tightening torque 

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

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

   Courtesy of MAZDA MOTORS CORP.

3. 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.

   Courtesy of MAZDA MOTORS CORP.

4. Remove the insulators using the following procedure:
   1. Disconnect the A/F sensor connector and clip shown in the figure.

      Courtesy of MAZDA MOTORS CORP.

   2. Remove the insulator shown in the figure.
      Fig 1: Insulator Nut With Torque Specification

      Courtesy of MAZDA MOTORS CORP.
   3. Remove the insulator shown in the figure.
      Fig 2: Insulator Bolt With Torque Specification

      Courtesy of MAZDA MOTORS CORP.
5. Remove the exhaust system. (See EXHAUST SYSTEM REMOVAL/INSTALLATION ).
6. Remove the exhaust manifold bracket using the following procedure:
   1. Loosen the bolt shown in the figure.

      Courtesy of MAZDA MOTORS CORP.

   2. Remove the bolts in the order shown in the figure, then remove the exhaust manifold bracket.
      Fig 3: Exhaust Manifold Bracket Bolts Loosening Sequence

      Courtesy of MAZDA MOTORS CORP.
   • 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.
        Fig 4: Exhaust Manifold Bracket Bolts Tightening Sequence

        Courtesy of MAZDA MOTORS CORP.
     2. Loosen the bolt shown in the figure until it is no longer seated on the surface.

        Courtesy of MAZDA MOTORS CORP.

     3. Tighten the bolt in the order shown in the figure.
        Fig 5: Exhaust Manifold Bracket Bolts Tightening Sequence

        Courtesy of MAZDA MOTORS CORP.

        Tightening torque 

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

7. Remove the bracket No. 1 (drive shaft bracket). (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION ).
8. Remove the transfer bracket and transfer. (AWD) (See TRANSFER REMOVAL/INSTALLATION [FW6AX-EL] ).
9. Remove the starter. (See STARTER REMOVAL/INSTALLATION ).
10. Remove the coolant control valve. (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION ).
11. Fix the drive plate using the crankshaft pulley lock bolt.
12. Remove the torque converter installation nut from the starter installation hole. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6AX-EL] .(AWD))
13. Disconnect the engine and transaxle, and lower only the engine from the engine lifter. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FW6AX-EL] .(AWD))
14. Remove the generator. (See GENERATOR REMOVAL/INSTALLATION ).
15. Remove the intake-air system. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION ).
16. Remove the oil separator. (See POSITIVE CRANKCASE VENTILATION (PCV) VALVE REMOVAL/INSTALLATION ).
17. Remove the knock sensor (KS). (See KNOCK SENSOR (KS) REMOVAL/INSTALLATION ).
18. Remove the fuel injectors. (See FUEL INJECTOR REMOVAL/INSTALLATION ).
19. Remove the camshaft position (CMP) sensor. (See CAMSHAFT POSITION (CMP) SENSOR REMOVAL/INSTALLATION ).
20. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION ).
21. Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION ).
22. Remove the electric variable valve timing motor/driver. (See ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER REMOVAL/INSTALLATION ).
23. Remove the OCV for No. 1 cylinder deactivation. (See OIL CONTROL VALVE (OCV) FOR CYLINDER DEACTIVATION REMOVAL/INSTALLATION ).
24. Remove the OCV for No. 4 cylinder deactivation. (See OIL CONTROL VALVE (OCV) FOR CYLINDER DEACTIVATION REMOVAL/INSTALLATION ).
25. Remove the oil filter. (See OIL FILTER REPLACEMENT ).
26. Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION ).
27. Remove the engine oil temperature sensor/engine oil pressure sensor. (See ENGINE OIL TEMPERATURE SENSOR/ENGINE OIL PRESSURE SENSOR REMOVAL/INSTALLATION ).
28. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION ).
29. Remove the dipstick.
30. Remove the purge solenoid valve, catch tank and bracket as a single unit. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION ).
31. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION ).
32. Remove the wiring harness bracket using the following procedure:
    1. Remove the clip shown in the figure.

       Courtesy of MAZDA MOTORS CORP.

    2. Remove the bolts shown in the figure.
       Fig 6: Wiring Harness Bracket Bolts With Torque Specification

       Courtesy of MAZDA MOTORS CORP.
33. Remove the emission harness.
34. Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION ).
35. Remove the water inlet pipe and flange component. (See CYLINDER HEAD GASKET REPLACEMENT ).
36. Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION ).
37. Remove in the order indicated in the table.
38. Assemble in the reverse order of disassembly.
    Fig 7: Oil Filter Body, Exhaust Manifold Bracket Components With Torque Specification

    Courtesy of MAZDA MOTORS CORP.
    PART SPECIFICATION
    
    

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