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Mazda SKYACTIV-G 2.5, Workshop Manual

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Mazda SKYACTIV-G 2.5 Workshop Manual Download Page 58

MECHANICAL 

01-10–45

01-10

Piston Ring Assembly Note

Note

•

It is not required to position the end gap between the top ring and second ring.

1. Assemble the oil ring so that the end gap of each 

oil ring rail does not overlap as shown in the 

figure.

2. Assemble so that the identification paint marks on 

the top and second rings are visible to the right 

side of each end gap.

Note

•

If there are no identification paint marks on 

the top and second rings, place the ring with 

the bigger inner circumference at the top as 

shown in the figure. 

30

°

30

°

PISTON PIN AXIS

LOWER OIL RING RAIL

UPPER OIL RING RAIL

OIL RING SPACER

bpe2ue00000043

TOP RING

END GAP

IDENTIFICATION PAINT MARK

SECOND RING

bpe1ze00000047

TOP RING

NOTCH

NOTCH

SECOND RING

bpe2ue00000044

1A36-1U-12L.book  45 ページ  ２０１２年１２月１０日　月曜日　午前９時２５分

Summary of Contents for SKYACTIV-G 2.5

Page 1: ...me of printing As modifications affecting repair or maintenance occur relevant information supplementary to this volume will be made available at Mazda dealers This manual should be kept up to date Ma...

Page 2: ......

Page 3: ...effective methods of performing service and repair Some require tools specifically designed for a specific purpose Persons using procedures and tools which are not recommended by Mazda Motor Corporat...

Page 4: ...ial Service Tools 00 00 6 Disassembly 00 00 6 Inspection During Removal Disassembly 00 00 7 Arrangement of Parts 00 00 7 Cleaning of Parts 00 00 7 Reassembly 00 00 7 Adjustment 00 00 8 Rubber Parts an...

Page 5: ...sealant are shown in the overview illustration In addition symbols indicating parts requiring the use of special service tools or equivalent are also shown 3 Procedure steps are numbered and the part...

Page 6: ...iling Link Ball Joint Removal Note Bolt 5 Lower trailing link 6 Dust boot lower trailing link 7 Split pin 8 Nut 9 Upper trailing link ball joint See 02 14 5 Upper Trailing Link Ball Joint Removal Note...

Page 7: ...ormation that will help you to complete a particular procedure Specification The values indicate the allowable range when performing inspections or adjustments Upper and lower limits The values indica...

Page 8: ...p down If there is no tolerance in the SI unit value after conversion rounding off is to within the number of significant digits If there is tolerance in the SI unit value and the figure after convers...

Page 9: ...lent when they are required Disassembly If the disassembly procedure is complex requiring many parts to be disassembled all parts should be marked in a place that will not affect their performance or...

Page 10: ...ing of Parts All parts to be reused should be carefully and thoroughly cleaned in the appropriate method Warning Using compressed air can cause dirt and other particles to fly out causing injury to th...

Page 11: ...bing Prevent gasoline or oil from getting on rubber parts or tubing Torque Formulas When using a torque wrench SST or equivalent combination the written torque must be recalculated due to the extra le...

Page 12: ...GENERAL INFORMATION 00 00 9 00 00 Vise When using a vise put protective plates in the jaws of the vise to prevent damage to parts End Of Sie PROTECTIVE PLATES bpe2ue00000120...

Page 13: ......

Page 14: ...l Disassembly Note 01 10 18 CYLINDER BLOCK DISASSEMBLY I 01 10 19 Dual mass Flywheel MTX Drive Plate ATX Installation Bolt Disassembly Note 01 10 20 Dual mass Flywheel Disassembly Note MTX 01 10 21 Re...

Page 15: ...LY 01 10 67 Oil Pump Chain Assembly Note 01 10 69 Timing Chain Assembly Note 01 10 71 Engine Front Cover Assembly Note 01 10 74 Oil Pan Assembly Note 01 10 77 Electric Variable Valve Timing Motor Driv...

Page 16: ...C VARIABLE VALVE TIMING ACTUATOR INSPECTION id011000555500 Caution Do not disassemble the electric variable valve timing actuator because it is a precision unit 1 Rotate the eccentric shaft of the ele...

Page 17: ...le to terminal A negative battery cable to terminal B Positive battery cable to terminal B negative battery cable to terminal A 2 Apply battery positive voltage between the OCV terminals and verify th...

Page 18: ...hly If it does not rotate smoothly replace the rocker arm 2 Visually inspect the rocker arm surface where it contacts the HLA and valve stem for wear or damage If there is any malfunction replace the...

Page 19: ...sed from the side of the plate 5 Adjust the bolts and nuts so that the plate and arms are parallel 6 Tighten the SSTs bolts and nuts to affix the SST firmly 7 Install the engine to the SST engine stan...

Page 20: ...osition When rotating the camshaft using a wrench on the cast hexagon the wrench may contact the rocker arm and damage the rocker arm To prevent damage to the rocker arm when holding the camshaft on t...

Page 21: ...ated in the table R 1 A 3 A 2 13 17 16 15 14 24 18 19 21 20 SST SST 12 4 5 22 23 9 10 8 7 11 6 SST R R R bpe1ze00000062 1 Dipstick 2 Cylinder head cover 3 Oil shower pipe 4 Spark plug 5 Water pump pul...

Page 22: ...ulley Lock Bolt Disassembly Note 7 Crankshaft pulley 8 Electric variable valve timing motor driver 9 Oil pan See 01 10 10 Oil Pan Disassembly Note 10 Engine front cover See 01 10 10 Engine Front Cover...

Page 23: ...emove the engine front cover installation bolts 2 Using a screwdriver wrapped in a cloth peel the sealant away a little at a time and remove the engine front cover Caution Do not apply excessive force...

Page 24: ...crewdriver and release the plunger lock Note When moving the exhaust camshaft back and forth the timing chain pushes the plunger in the chain tensioner making it easier to operate the link plate 2 Pus...

Page 25: ...the balancer shaft sprocket and oil pump driven sprocket installation bolts Note At this stage only loosen the installation bolts do not remove them Remove the bolts after removing the oil pump chain...

Page 26: ...hain tensioner with the plunger pressed Note The wire or paper clip secures the plunger and the tension can be released 6 Remove the oil pump chain tensioner 7 Remove the oil pump chain and balancer s...

Page 27: ...sition When rotating the camshaft using a wrench on the cast hexagon the wrench may contact the rocker arm and damage the rocker arm To prevent damage to the rocker arm when holding the camshaft on th...

Page 28: ...le valve timing actuator See 01 10 16 Electric Variable Valve Timing Actuator Hydraulic Variable Valve Timing Actuator Disassembly Note 2 OCV 3 Camshaft cap See 01 10 16 Camshaft Cap Disassembly Note...

Page 29: ...r three passes in the order shown in the figure and remove the camshaft caps Rocker Arm Disassembly Note 1 Keep the rocker arms in the order of removal to enable reassembly in their original positions...

Page 30: ...dicated in the table 3 1 2 R R 7 SST SST 5 4 6 9 8 bpe1ze00000013 1 Thermostat cover 2 Thermostat 3 Water outlet 4 Valve keeper See 01 10 18 Valve Keeper Disassembly Note 5 Upper valve spring seat 6 V...

Page 31: ...te 1 Remove the valve keeper using the SSTs Valve Seal Disassembly Note 1 Remove the valve seal using the SST or pliers End Of Sie 49 0636 100B 49 B012 0A2A bpe1ze00000014 49 S120 170 VALVE SEAL VALVE...

Page 32: ...3 R ATX MTX 10 11 bpe5ue00000002 1 Knock sensor KS 2 Oil separator 3 Dual mass flywheel MTX drive plate ATX installation bolt See 01 10 20 Dual mass Flywheel MTX Drive Plate ATX Installation Bolt Dis...

Page 33: ...secondary flywheel side against rotation Warning If all of the bolts are removed without locking the dual mass flywheel secondary flywheel side against rotation the dual mass flywheel primary or secon...

Page 34: ...ing the dual mass flywheel secondary flywheel side against rotation Rear Oil Seal Disassembly Note 1 Cut the oil seal lip using a utility knife 2 Remove the oil seal using a flathead screwdriver with...

Page 35: ...Note 3 Lower connecting rod bearing See 01 10 23 Connecting Rod Bearing Disassembly Note 4 Piston connecting rod See 01 10 23 Piston Connecting Rod Disassembly Note 5 Upper connecting rod bearing See...

Page 36: ...removed connecting rod bearings are to be kept so that they can be assembled to the same positions and in the direction as before removal Piston Connecting Rod Disassembly Note 1 Before removing the p...

Page 37: ...removing the lower cylinder block inspect the crankshaft end play See 01 10 36 CRANKSHAFT INSPECTION 2 Loosen the lower cylinder block installation bolts B in two or three passes in the order shown in...

Page 38: ...ensor signal detection installed to the crankshaft is larger than the counterweight Therefore set wood blocks or similar objects on the both sides of the crankshaft so that the plate does not contact...

Page 39: ...011000501300 1 Measure the contact width of the valve face and the valve seat using the valve lapping compound If it is not within the specification resurface the valve seat using the 45 valve seat cu...

Page 40: ...ure the length of the each valve using a vernier caliper If it is less than the minimum specification replace the valve Standard valve length IN 107 00 107 60 mm 4 2127 4 2362 in EX 117 09 117 69 mm 4...

Page 41: ...de from the outer diameter of the corresponding valve stem If it exceeds the maximum specification replace the valve or valve guide Standard clearance between valve stem and guide IN 0 025 0 060 mm 0...

Page 42: ...the specification Standard valve guide projection height IN 16 4 17 0 mm 0 646 0 669 in EX 16 4 17 0 mm 0 646 0 669 in End Of Sie VALVE SPRING INSPECTION id011000501400 Caution The valve springs diff...

Page 43: ...ace the valve spring Maximum valve spring off square IN 2 0 1 7 mm 0 067 in EX 2 0 1 7 mm 0 067 in End Of Sie CAMSHAFT INSPECTION id011000501500 1 Set the No 1 and No 5 journals of the camshaft on V b...

Page 44: ...Cut the plastigauge to the same length as the journal width and position it parallel to the camshaft 4 Install the camshaft caps See 01 10 59 CYLINDER HEAD ASSEMBLY II 5 Remove the camshaft caps See...

Page 45: ...r to oil jet valve A and verify that air passes through oil jet valve B If air does not flow replace the oil jet valve If there is air flow with air compressor of less than 180 kPa 1 84 kgf cm2 26 1 p...

Page 46: ...op 0 04 0 08 mm 0 002 0 003 in Second 0 03 0 07 mm 0 0012 0 0027 in Oil 0 04 0 12 mm 0 002 0 004 in Maximum clearance between piston ring and ring groove Top 0 12 mm 0 0047 in Second 0 10 mm 0 0039 in...

Page 47: ...e piston pin hole diameter and the piston pin outer diameter If it is not within the specification replace the piston or the piston pin Standard clearance between piston pin hole diameter and piston p...

Page 48: ...Of Sie CONNECTING ROD CLEARANCE INSPECTION id011000507600 1 Measure the side clearance at the large end of the connecting rod using a feeler gauge If it exceeds the maximum specification replace the...

Page 49: ...1 in Maximum crankshaft end play 0 30 mm 0 012 in Thrust bearing size STD 2 500 2 550 mm 0 0985 0 1003 in OS 0 25 2 625 2 675 mm 0 1034 0 1053 in 2 Measure the runout of the main journal using a V blo...

Page 50: ...TD 2 489 2 510 mm 0 0980 0 0988 in OS 0 25 2 614 2 617 mm 0 10292 0 10303 in OS 0 50 2 739 2 742 mm 0 10784 0 10795 in End Of Sie DUAL MASS FLYWHEEL INSPECTION id011000501900 Caution Do not rework the...

Page 51: ...inspect the dual mass flywheel for crack If there is any crack replace the dual mass flywheel 2 Visually inspect the ring gear on the dual mass flywheel for damage If there is any damage replace the d...

Page 52: ...ing End Of Sie BOLT INSPECTION id011000503300 1 Measure the length of the each bolt If it exceeds the maximum specification replace the bolt Standard cylinder head bolt length 145 2 145 8 mm 5 717 5 7...

Page 53: ...HE BOLTS UNTIL BOLTS ARE TORQUE FREE 30 34 3 1 3 4 23 25 57 5 62 5 bpe5ue00000004 1 Upper cylinder block 2 Oil jet valve 3 Thrust bearing See 01 10 41 Thrust Bearing And Main Bearing Assembly Note 4 U...

Page 54: ...liding surface Main bearing 1 Apply clean engine oil to the main bearings 2 Align the positioning tab of the main bearing with the positioning groove of the lower and upper cylinder block and assemble...

Page 55: ...t C and tighten the bolts to the specified tightening torque in the order of C B and A Tightening torque 20 26 N m 2 1 2 6 kgf m 15 19 ft lbf Lower Cylinder Block Assembly Note 1 Completely clean and...

Page 56: ...the lower cylinder block installation bolts using the following procedure 1 Apply clean engine oil to the seating surface and thread of lower cylinder block installation bolts A A A ENGINE FRONT LOWE...

Page 57: ...wipe away the excess silicone sealant If silicone sealant does not protrude to the rear oil seal press in part remove the lower cylinder block and apply silicone sealant again Piston Pin Assembly Not...

Page 58: ...ntification paint marks on the top and second rings are visible to the right side of each end gap Note If there are no identification paint marks on the top and second rings place the ring with the bi...

Page 59: ...engine oil to the sliding part when assembling 1 Apply engine oil to the connecting rod bearings 2 Align the positioning tab of the connecting rod bearing with the positioning groove of the connecting...

Page 60: ...ecting rod caps 2 Tighten the connecting rod cap bolts in the following two steps Tightening procedure Step 1 26 32 N m 2 7 3 2 kgf m 20 23 ft lbf Step 2 80 100 Pilot Bearing Assembly Note 1 Install n...

Page 61: ...T 9 R ATX MTX 10 11 bpe5ue00000005 1 Balancer unit See 01 10 49 Balancer Unit Assembly Note 2 Oil pump See 01 10 50 Oil Pump Assembly Note 3 Oil strainer 4 Water pump See 01 10 51 Water Pump Assembly...

Page 62: ...htening torque 2 Retighten the bolts in the order of the numbers indicated in the figure Tightening torque 30 36 N m 3 1 3 6 kgf m 23 26 ft lbf 4 3 1 2 BALANCER UNIT ENGINE FRONT 5 6 bpe1ze00000051 In...

Page 63: ...the specified torque Note The tightening order for the two bolts is optional Tightening torque 20 26 N m 2 1 2 6 kgf m 15 19 ft lbf 3 Finally tighten the bolt shown in the figure to the specified tor...

Page 64: ...therwise it could leak engine coolant and damage the engine 1 Insert a new water pump gasket into the water pump groove 2 Install the water pump 3 Tighten the bolts in the order shown in the figure Ti...

Page 65: ...the rear oil seal into the cylinder block by hand 3 Tap the oil seal in evenly using the SST and a hammer Rear oil seal press on amount 0 0 5 mm 0 0 019 in A HAMMER CYLINDER BLOCK VIEW FROM A 49 S033...

Page 66: ...mage and removal of the end plate Dual mass Flywheel MTX Drive Plate ATX Installation Bolt Assembly Note Dual mass flywheel installation bolt MTX 1 Hold the crankshaft using the SST 49 E011 1A0 2 Temp...

Page 67: ...lbf Drive plate installation bolt ATX 1 Hold the crankshaft using the SST 2 Tighten the new bolts in two or three passes in the order shown in the figure Tightening torque 108 116 N m 11 1 11 8 kgf m...

Page 68: ...82 112 71 97 bpe1ze00000017 1 Lower valve spring seat 2 Valve seal See 01 10 56 Valve Seal Assembly Note 3 Valve 4 Valve spring See 01 10 56 Valve Spring Assembly Note 5 Upper valve spring seat 6 Valv...

Page 69: ...s differ depending on IN and EX sides Therefore verify the free length or identification paint beforehand and assemble the valve springs correctly 1 Assemble the valve spring with the small diameter s...

Page 70: ...tlet Assembly Note 1 Install the water outlet gasket with the bead of the gasket facing the direction shown in the figure 2 Temporarily tighten the water outlet installation bolts 49 0636 100B 49 B012...

Page 71: ...orque 8 11 N m 82 112 kgf cm 71 97 in lbf Note The tightening order for the remaining 3 bolts is optional Thermostat Assembly Note 1 Install the thermostat with the jiggle pin aligned with the notch o...

Page 72: ...position When rotating the camshaft using a wrench on the cast hexagon the wrench may contact the rocker arm and damage the rocker arm To prevent damage to the rocker arm when holding the camshaft on...

Page 73: ...H OIL COOLER WITHOUT OIL COOLER 3 3 20 26 2 1 2 6 15 19 10 bpe5ue00000007 1 Cylinder head gasket 2 Cylinder head See 01 10 61 Cylinder Head Assembly Note 3 Water inlet pipe See 01 10 62 Water Inlet Pi...

Page 74: ...bolt length L 146 5 mm 5 767 in 1 When a cylinder head bolt is reused apply engine oil to any part of the following Bolt seating surface Cylinder head seating surface 2 Tighten the cylinder head bolt...

Page 75: ...ipe stay 2 Apply engine coolant to the O ring 3 Install the O ring to the water inlet pipe 4 Insert the water inlet pipe into the water pump being careful not to damage the O ring 5 Install the water...

Page 76: ...g the plunger up and down 3 Press the end of the plunger in the oil and verify that there is no rebounding feel If rebounding feel cannot be eliminated replace the HLA 2 Install the HLAs to their orig...

Page 77: ...0 003 in3 or less of oil to journal No 6 2 Apply gear oil SAE No 90 or equivalent or engine oil to the following locations of each camshaft Thrust surface of front journal 3 As shown in the figure ali...

Page 78: ...head or the exhaust side rear camshaft cap Caution Verify that there is no adhesive agent on the journal Adhesive agent bead width 0 5 1 5 mm 0 02 0 05 in 6 Install the camshaft caps in the marked num...

Page 79: ...e Timing Actuator Assembly Note 1 Align the knock pin on the end of the camshaft with the notch on the actuator intake side or knock pin installation hole exhaust side then install the actuator to the...

Page 80: ...the engine could be damaged When rotating the camshaft with the timing chain removed rotate it after lowering the piston from the top dead center position When rotating the camshaft using a wrench on...

Page 81: ...ST OIL OIL 20 26 2 1 2 6 15 19 90 110 9 2 11 67 81 55 65 R R 1 SEALANT SEALANT SEALANT SEALANT SEALANT SEALANT 1 1 1 1 1 8 11 N m 82 112 kgf m 71 97 ft lbf 1 SEALANT SEALANT N m kgf m ft lbf 1 20 30 2...

Page 82: ...ing Chain Assembly Note 11 Chain guide No 1 See 01 10 71 Timing Chain Assembly Note 12 Tensioner arm See 01 10 71 Timing Chain Assembly Note 13 Chain tensioner See 01 10 71 Timing Chain Assembly Note...

Page 83: ...ing the SST 9 Tighten the oil pump driven sprocket installation bolt Tightening torque 20 30 N m 2 1 3 0 kgf m 15 22 ft lbf 10 Tighten the balancer shaft sprocket installation bolt Tightening torque 3...

Page 84: ...igure Note The timing mark of SKYACTIV G 2 5 is not completely parallel with the upper surface of the cylinder head If they are not in the position shown in the figure rotate the camshaft and cranksha...

Page 85: ...ming chain If a new chain tensioner is used remove the installed stopper 6 Install the chain guide No 1 7 Verify that there is no looseness in the timing chain and re verify that each sprocket is in t...

Page 86: ...he crankshaft clockwise two turns and inspect the valve timing Note The timing mark of SKYACTIV G 2 5 is not completely parallel with the upper surface of the cylinder head CYLINDER HEAD UPPER SURFACE...

Page 87: ...using the engine front cover installation bolts clean any old sealant from the bolts Caution Apply the silicon sealant in a single unbroken line To prevent silicone sealant from hardening adhere the e...

Page 88: ...e figure 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 A mm in SEALANT SEALANT 90 10 0 39 SECTION D D 0 5 1 5 mm 0 02 0 05 in SEALANT SEALANT ENGINE FRONT COVER A 10 0 3...

Page 89: ...olt 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 7 Prepare an appropriate M...

Page 90: ...e cylinder block and oil pan 2 When reusing the oil pan installation bolts clean any old sealant from the bolts Caution Apply the silicon sealant in a single unbroken line around the whole perimeter T...

Page 91: ...tall the oil pan to the cylinder block 2 Temporarily tighten the two bolts shown in the figure 3 Tighten the bolts in the order shown in the figure Tightening torque 8 11 N m 82 112 kgf cm 71 97 in lb...

Page 92: ...e joint groove of the eccentric shaft in any position and it will not lead to vehicle damage or performance reduction 1 Before installation rotate the joint on the end of the electric variable valve t...

Page 93: ...0 0 5 mm 0 0 019 in Crankshaft Pulley Lock Bolt Assembly Note 1 Hold the crankshaft using the SST 2 Tighten the crankshaft pulley lock bolt in the order shown in the following two steps Tightening pro...

Page 94: ...er pump hole as shown in the figure 3 Insert an appropriate bolt length 70 mm 2 8 in into the water pump hole shown in the figure and lock the water pump pulley against rotation 4 Completely tighten t...

Page 95: ...mpletely clean and remove any oil dirt sealant or other foreign matter from the seal surface To prevent silicone sealant from hardening adhere the cylinder head cover and the cylinder head within 10 m...

Page 96: ...YLINDER HEAD ENGINE FRONT COVER ENGINE FRONT COVER MATCHING SURFACE EXHAUST SIDE REAR CAMSHAFT CAP A VIEW FROM A CYLINDER HEAD ENGINE FRONT COVER B VIEW FROM B 3 13 mm 0 2 0 5 in CYLINDER HEAD EXHAUST...

Page 97: ......

Page 98: ...m and guide IN 0 025 0 060 mm 0 0010 0 0023 in EX 0 030 0 065 mm 0 0012 0 0025 in Maximum clearance between valve stem and guide 0 10 mm 0 0039 in Standard valve guide projection height IN 16 4 17 0 m...

Page 99: ...ndard bearing oil clearance at the large end of the connecting rod 0 026 0 052 mm 0 0011 0 0020 in Maximum bearing oil clearance at the large end of the connecting rod 0 10 mm 0 0039 in Connecting rod...

Page 100: ...10 1A0 2 Engine hanger set 1 49 0107 680A 2 Engine stand 1 49 E011 1A0 2 Ring gear brake set 1 49 0636 100B 2 Valve spring lifter arm 1 49 B012 0A2A 2 Pivot 1 49 S120 170 2 Valve seal remover 1 49 S12...

Page 101: ......

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