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

Gasket Quantity: 1 Location of use: Water outlet component

1. To enable to install the SST, disconnect the clip shown in the figure and set the wiring harness aside.
   Fig 1: Intake Manifold And Clip

   Courtesy of MAZDA MOTORS CORP.
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 2: Intake Manifold And SST (Engine Front Side)

   Courtesy of MAZDA MOTORS CORP.

   Engine rear side 

   Fig 3: Installing SST With Bolt

   Courtesy of MAZDA MOTORS CORP.

   Tightening torque 

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

3. Engage the hooks of the SST (49 L017 5A0) to the SST (49 UN30 3050).
   Fig 4: Hooks Of SST

   Courtesy 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: Precautions For Do Not Up Engine

   Courtesy of MAZDA MOTORS CORP.
5. Remove the insulator shown in the figure.
   Fig 6: Removing Insulator With Nut And Bolt With Torque Specifications

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

      MTX 

      Fig 7: Exhaust Manifold Bracket, Cylinder Block, Bolt And Transaxle (MTX)

      Courtesy of MAZDA MOTORS CORP.

      ATX 

      Fig 8: Exhaust Manifold Bracket, Cylinder Block, Bolt And Transaxle (ATX)

      Courtesy of MAZDA MOTORS CORP.
   2. Remove the bolts in the order shown in the figure, then remove the exhaust manifold bracket.

   MTX 

   Fig 9: Exhaust Manifold Bracket (MTX) Bolts Loosening Sequence

   Courtesy of MAZDA MOTORS CORP.

   ATX 

   Fig 10: Exhaust Manifold Bracket (ATX) 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.

        MTX 

        Fig 11: Exhaust Manifold Bracket (MTX) Bolts Tightening Sequence

        Courtesy of MAZDA MOTORS CORP.

        ATX 

        Fig 12: Exhaust Manifold Bracket (ATX) 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.

        MTX 

        Fig 13: Exhaust Manifold Bracket, Cylinder Block, Bolt And Transaxle (MTX)

        Courtesy of MAZDA MOTORS CORP.

        ATX 

        Fig 14: Exhaust Manifold Bracket, Cylinder Block, Bolt And Transaxle (ATX)

        Courtesy of MAZDA MOTORS CORP.
     3. Tighten the bolt in the order shown in the figure.

        MTX 

        Fig 15: Exhaust Manifold Bracket (MTX) Bolts Tightening Sequence

        Courtesy of MAZDA MOTORS CORP.

     Tightening torque 

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

     ATX 

     Fig 16: Exhaust Manifold Bracket (ATX) Bolts Tightening Sequence

     Courtesy of MAZDA MOTORS CORP.

     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 [FW6AX-EL] .)
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 [C66M-R](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 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 oil filter. (See OIL FILTER REPLACEMENT .)
24. Remove the oil cooler. (If equipped) (See OIL COOLER REMOVAL/INSTALLATION .)
25. Remove the engine oil solenoid valve. (See ENGINE OIL SOLENOID VALVE REMOVAL/INSTALLATION .)
26. Remove the crankshaft position (CKP) sensor. (See CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION .)
27. Remove the dipstick.
28. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION .)
29. Remove the wiring harness bracket shown in the figure.
    Fig 17: Removing Wiring Harness Bracket With Bolts

    Courtesy of MAZDA MOTORS CORP.
30. Remove the emission harness.
31. Remove the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
32. Remove the water inlet pipe. (See CYLINDER HEAD GASKET REPLACEMENT .)
33. Remove the water pump. (See WATER PUMP REMOVAL/INSTALLATION .)
34. Remove the clutch cover and clutch disc. (MTX) (See CLUTCH UNIT REMOVAL/INSTALLATION [C66M-R] .)
35. Remove in the order indicated in the table.
36. Assemble in the reverse order of disassembly.