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: Positioning Pins Project To Outside Of Engine

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.

Fig 2: Tapping Positioning Pins To Seal Surface Side
Courtesy of MAZDA MOTORS CORP.
CAUTION:
- If a bolt with sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.
Fig 3: Precautions For Cracks In Cylinder Block And Cylinder Head
Courtesy of MAZDA MOTORS CORP.
When reusing an engine front cover installation bolts, remove sealant adhering to the bolts.
CAUTION:
- If oil, dirt and sealant remains on the sealant application area, the silicone sealant will not seal which will cause oil leakage.
Completely clean and remove any oil, dirt, sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.
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.
Apply silicone sealant (TB1217D or equivalent) to the engine front cover as shown in the figure.
SKYACTIV-G 2.0

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

SKYACTIV-G 2.5

Fig 5: Applying Silicone Sealant To Engine Front Cover (SKYACTIV-G 2.5)
Courtesy 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.
Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

Fig 6: Applying Silicone Sealant To Gap Between Cylinder Head And Cylinder Block
Courtesy of MAZDA MOTORS CORP.
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: Drive Belt Auto Tensioner Installation Bolt Hole
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 bolts with new washer.
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}
NOTE:
- Install stud bolts because there are no stud bolts installed on a new engine front cover.
- If the engine front cover is reused, tighten the stud bolts because they may have loosened.
Tighten the engine front cover stud bolts.

Fig 9: Tightening Engine Front Cover Stud Bolts
Courtesy of MAZDA MOTORS CORP.

Tightening torque

7-13 N.m {72-132 kgf.cm, 62-115 in.lbf}
Install the ground cable and wiring harness bracket shown in the figure.

Fig 10: Installing Ground Cable And Wiring Harness Bracket
Courtesy of MAZDA MOTORS CORP.
Install the insulator shown in the figure.

Fig 11: Installing Insulator

Courtesy of MAZDA MOTORS CORP.