Mazda SKYACTIV-G 2.5 Workshop Manual

Engine

CONTENTS

Workshop Manual SKYACTIV-G 2.5

FOREWORD

This manual explains the service points for the above-indicated automotive system. This manual covers all models with the above-indicated automotive system, not any one specific model.

In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully.

All the contents of this manual, including drawings and specifications, are the latest available at the time 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.

Title Section

GENERAL INFORMATION 00

ENGINE

PRINTED IN U.S.A., DECEMBER 2012 Form No. 1A36–1U–12L Part No. 9999–95–EWPY–14

Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or advance notice.

All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechanical—including photocopying and recording and the use of any kind of information storage and retrieval system—without permission in writing.

Mazda Motor Corporation

HIROSHIMA, JAPAN

WARNING

Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda-trained technicians in mind. This manual may be useful to non-Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are expected to at least know general safety procedures.

This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures.

The procedures recommended and described in this manual are 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 Corporation must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation.

Parts should be replaced with genuine Mazda replacement parts or with parts which match the quality of genuine Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized.

Mazda Motor Corporation is not responsible for any problems which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service-related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual.

Mazda Motor Corporation

GENERAL INFORMATION

Toc of SC T

GENERAL INFORMATION . . . .00-00

Toc of SC T

00-00 GENERAL INFORMATION

SECTION

00-00

HOW TO USE THIS MANUAL . . . . . . . . . 00-00–1

Range of Topics . . . . . . . . . . . . . . . . . . 00-00–1

Service Procedure . . . . . . . . . . . . . . . . 00-00–2

Symbols . . . . . . . . . . . . . . . . . . . . . . . . 00-00–4

Advisory Messages. . . . . . . . . . . . . . . . 00-00–4

UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–5

Conversion From SI Units (Système

International d'Unités) . . . . . . . . . . . . . 00-00–5

Number Of Digits For

Converted Values . . . . . . . . . . . . . . . . 00-00–5

Converted Value Rounding Off And

Rounding Up/down . . . . . . . . . . . . . . . 00-00–5

ABBREVIATIONS. . . . . . . . . . . . . . . . . . . 00-00–6

FUNDAMENTAL PROCEDURES. . . . . . . 00-00–6

End of Toc

WM: GENERAL INFORMATION

HOW TO USE THIS MANUAL

Range of Topics

• This manual contains procedures for performing all required service operations. The procedures are divided into the following basic operations:

— Removal/Installation — Disassembly/Assembly — Replacement — Inspection — Adjustment

• Simple operations which can be performed easily just by looking at the actual unit (i.e., removal/installation of parts, cleaning of parts, and visual inspection) have been omitted.

Preparation of Tools and Measuring

Equipment . . . . . . . . . . . . . . . . . . . . . 00-00–6

Special 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 and Tubing . . . . . . . . . . . 00-00–8

Torque Formulas . . . . . . . . . . . . . . . . . 00-00–8

Vise . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00–9

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00-00–1

GENERAL INFORMATION

Service Procedure Inspection, adjustment

• Inspection and adjustment procedures are divided into steps. Important points regarding the location and contents of the procedures are explained in detail and shown in the illustrations.

Fluid Pressure Inspection

1. Assemble the SSTs as shown in the figure.

49 1232 670A

SHOWS PROCEDURE ORDER FOR SERVICE

Tightening torque

39—49 N·m {4.0—5.0 kgf·m, 29—36 ft·lbf}

49 H002 671

Caution

49 H032 322

Connect the gauge set from under the vehicle to prevent contact with the drive belt and the cooling fan.

SHOWS TIGHTENING TORQUE SPECIFICATIONS

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Repair procedure

1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only removal/installation procedures that need to be performed methodically have written instructions.

2. Expendable parts, tightening torques, and symbols for oil, grease, and 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 that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or additional information concerning a procedure. Refer to this information when servicing the related part.

00-00–2

GENERAL INFORMATION

GREASE

Procedure

"Removal/Installation" Portion

"Inspection After Installation" Portion

INSTALL THE PARTS BY PERFORMING STEPS

—

1—3 IN REVERSE ORDER

SHOWS THERE ARE REFERRAL NOTES FOR SERVICE

LOWER TRAILING LINK, UPPER TRAILING LINK REMOVAL/INSTALLATION

1. Jack up the rear of the vehicle and suppor t it with safety stands.

2. Remove the undercover. (See 01-10-4 Undercover Removal)

3. Remove in the order indicated in the table.

4. Install in the reverse order of removal.

5. Inspect the rear wheel alignment and adjust it if necessary.

SHOWS PROCEDURE ORDER FOR SERVICE

44—60 {4.4—6.2, 32—44}

SHOWS TIGHTENING TORQUE SPECIFICATIONS

SST

94—116 {9.5—11.9, 69—86}

Split pin

Nut

Lower trailing link ball joint

(See 02-14-5 Lower Trailing Link Ball Joint Removal Note) Bolt

Lower trailing link

Dust boot (lower trailing link)

GREASE

7 8 Nut 9 Upper trailing link ball joint

10 11 12

SHOWS SERVICE ITEM (S)

INDICATES ANY RELEVANT REFERENCES WHICH NEED TO BE FOLLOWED DURING INSTALLATION

SHOWS SPECIAL

SST

43—56 {4.3—5.8, 32—41}

SERVICE TOOL (SST) FOR SERVICE OPERATION

GREASE

SHOWS APPLICATION POINTS OF GREASE, ETC.

SHOWS NON-REUSEABLE PARTS

SHOWS DETAILS

118—156 {12.0—16.0, 87—115}

N·m {kgf·m, ft·lbf}

Split pin

(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)

Nut Upper trailing link

Dust boot (upper trailing link)

00-00

SHOWS TIGHTENING TORQUE UNITS

Lower Trailing Link Ball Joint, Upper Trailing Link Ball Joint Removal Note

Remove the ball joint using the SSTs.

SHOWS REFERRAL NOTES FOR SERVICE

49 T028 304

49 T028 305

UPPER TRAILING LINK

LOWER TRAILING LINK

SHOWS SPECIAL SERVICE TOOL (SST) NO.

KNUCKLE

49 T028 303

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00-00–3

GENERAL INFORMATION

OIL

BRAKE FLUID

ATF

GREASE

SEALANT

Symbols

• There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols

show application points or use of these materials during service.

Symbol Meaning Kind

OIL

BRAKE FLUID

ATF

GREASE

SEALANT

Apply oil New appropriate engine oil or gear oil

Apply brake fluid New appropriate brake fluid

Apply automatic transaxle/ transmission fluid

New appropriate automatic transaxle/ transmission fluid

Apply grease Appropriate grease

Apply sealant

Apply petroleum jelly

Appropriate sealant

Appropriate petroleum jelly

Replace part O-ring, gasket, etc.

SST

Use SST or equivalent

Appropriate tools

Advisory Messages

• You will find several Warnings, Cautions, Notes, Specifications and Upper and Lower Limits in this

manual.

Warning

• A Warning indicates a situation in which serious injury or death could result if the warning is ignored.

Caution

• A Caution indicates a situation in which damage to the vehicle or parts could result if the caution is ignored.

Note

• A Note provides added information 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 indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.

End Of Sie

00-00–4

GENERAL INFORMATION

UNITS

Electric current A (ampere) Electric power W (watt) Electric resistance ohm Electric voltage V (volt)

Length

Negative pressure

Positive pressure

Number of revolutions rpm (revolutions per minute)

To r qu e

Volum e

Weight

mm (millimeter) in (inch) kPa (kilo pascal) mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal)

kgf/cm psi (pounds per square inch)

N·m (Newton meter) kgf·m (kilogram force meter) kgf·cm (kilogram force centimeter) ft·lbf (foot pound force) in·lbf (inch pound force) L (liter) US qt (U.S. quart) Imp qt (Imperial quart) ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) g (gram) oz (ounce)

(kilogram force per square centimeter)

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00-00

Conversion From SI Units (Système International d'Unités)

• All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values.

Number Of Digits For Converted Values

• The number digits for converted values is the same as the number of significant figures

of the SI unit.

• For the torque value, the number of significant figures is, in principle, is 2 digits, in consideration of market practicalities. However, if the number of decimal places at the upper and lower limits of the converted value differs, the one with least number of decimal places is used. In addition, if the integer part is 3 digits or more, the integer part becomes the significant number of figures.

*1 : The number of significant figures is the number of digits from the left-most non-zero digit to the right-most digit

including 0. (Example: 0.12 is 2 digits, 41.0 is 3 digits)

Converted Value Rounding Off And Rounding Up/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 conversion indicates the upper limit, the number of digits is rounded down to within the number of significant figures. If it indicates the lower limit, they are rounded up to within the number of significant figures.

• Even if the SI unit value is the same, the converted value may differ based on whether that value is the upper or lower limit.

End Of Sie

00-00–5

GENERAL INFORMATION

ABBREVIATIONS

ATX Automatic Transaxle EX Exhaust HLA Hydraulic Lash Adjuster IN Intake MTX Manual Transaxle OCV Oil Control Valve TDC Top Dead Center SST Special Service Tool

End Of Sie

GAIHAN: -

FUNDAMENTAL PROCEDURES

Preparation of Tools and Measuring Equipment

• Be sure that all necessary tools and measuring equipment are available before starting any work.

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Special Service Tools

• Use special service tools or equivalent 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 external appearance and identified so that reassembly can be performed easily and efficiently.

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49 SE01 310

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00-00–6

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GENERAL INFORMATION

Inspection During Removal, Disassembly

• When removed, each part should be carefully inspected for malfunction, deformation, damage and other problems.

Arrangement of Parts

• All disassembled parts should be carefully arranged for reassembly.

• Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

00-00

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Cleaning 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 the eyes. Wear protective eye wear whenever using compressed air.

Reassembly

• Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.

• If removed, the following parts should be replaced with new ones:

— Oil seals — Gaskets — O-rings — Lockwashers — Cotter pins — Nylon nuts

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00-00–7

• Depending on location:

— Sealant and gaskets, or both, should be

applied to specified locations. When sealant is applied, parts should be installed before sealant hardens to prevent leakage.

— Oil should be applied to the moving

components of parts.

— Specified oil or grease should be applied at

the prescribed locations (such as oil seals) before reassembly.

Adjustment

• Use suitable gauges and testers when making adjustments.

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Rubber Parts and Tubing

• 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 length that the SST or equivalent adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you.

Torque Unit Formula

N·m N·m × [L/(L+A)]

kgf·m kgf·m × [L/(L+A)]

kgf·cm kgf·cm × [L/(L+A)]

ft·lbf ft·lbf × [L/(L+A)]

in·lbf in·lbf × [L/(L+A)]

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SST

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A : The length of the SST past the torque wrench drive. L : The length of the torque wrench.

GENERAL INFORMATION

Vise

• When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.

End Of Sie

00-00

PROTECTIVE PLATES

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00-00–9

ENGINE

Toc of SC T

MECHANICAL. . . . . . . . . . . . . .01-10

TECHNICAL DATA . . . . . . . . . . 01-50

Toc of SC T

01-10 MECHANICAL

SECTION

01-10

SERVICE TOOLS . . . . . . . . . . . 01-60

ELECTRIC VARIABLE VALVE TIMING

MOTOR/DRIVER INSPECTION . . . . . . . 01-10–2

HYDRAULIC VARIABLE VALVE TIMING

ACTUATOR INSPECTION . . . . . . . . . . . 01-10–3

ELECTRIC VARIABLE VALVE TIMING

ACTUATOR INSPECTION . . . . . . . . . . . 01-10–3

OIL CONTROL VALVE (OCV)

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–4

Coil Resistance Inspection . . . . . . . . . . 01-10–4

Spool Valve Operation Inspection . . . . . 01-10–4

HYDRAULIC LASH ADJUSTER (HLA)

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–5

ROCKER ARM INSPECTION. . . . . . . . . . 01-10–5

ENGINE OVERHAUL SERVICE

WARNING. . . . . . . . . . . . . . . . . . . . . . . . 01-10–5

ENGINE MOUNTING/DISMOUNTING . . . 01-10–6

Mounting . . . . . . . . . . . . . . . . . . . . . . . . 01-10–6

Dismounting . . . . . . . . . . . . . . . . . . . . . 01-10–6

TIMING CHAIN DISASSEMBLY. . . . . . . . 01-10–7

Water Pump Pulley

Disassembly Note . . . . . . . . . . . . . . . . 01-10–9

Crankshaft Pulley Lock Bolt

Disassembly Note . . . . . . . . . . . . . . . . 01-10–10

Oil Pan Disassembly Note. . . . . . . . . . . 01-10–10

Engine Front Cover

Disassembly Note . . . . . . . . . . . . . . . . 01-10–10

Front Oil Seal Disassembly Note . . . . . 01-10–11

Chain Tensioner Disassembly Note . . . 01-10–11

Oil Pump Chain Disassembly Note. . . . 01-10–12

CYLINDER HEAD DISASSEMBLY (I) . . . 01-10–14

Electric Variable Valve Timing Actuator,

Hydraulic Variable Valve Timing

Actuator Disassembly Note. . . . . . . . . 01-10–16

Camshaft Cap Disassembly Note . . . . . 01-10–16

Rocker Arm Disassembly Note . . . . . . . 01-10–16

HLA Disassembly Note . . . . . . . . . . . . . 01-10–16

Cylinder Head Disassembly Note . . . . . 01-10–16

CYLINDER HEAD

DISASSEMBLY (II) . . . . . . . . . . . . . . . . . 01-10–17

Valve Keeper Disassembly Note . . . . . . 01-10–18

Valve Seal 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

Rear Oil Seal Disassembly Note . . . . . 01-10–21

CYLINDER BLOCK

DISASSEMBLY (II) . . . . . . . . . . . . . . . . 01-10–22

Pilot Bearing Disassembly Note. . . . . . 01-10–23

Connecting Rod Cap

Disassembly Note . . . . . . . . . . . . . . . 01-10–23

Connecting Rod Bearing

Disassembly Note . . . . . . . . . . . . . . . 01-10–23

Piston, Connecting Rod

Disassembly Note . . . . . . . . . . . . . . . 01-10–23

Snap Ring Disassembly Note. . . . . . . . 01-10–24

Lower Cylinder Block

Disassembly Note . . . . . . . . . . . . . . . 01-10–24

Thrust Bearing And Main Bearing

Disassembly Note . . . . . . . . . . . . . . . 01-10–25

Crankshaft Disassembly Note . . . . . . . 01-10–25

CYLINDER HEAD INSPECTION. . . . . . . 01-10–25

VALVE SEAT INSPECTION/REPAIR. . . . 01-10–26

VALVE, VALVE GUIDE

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–27

VALVE GUIDE REPLACEMENT . . . . . . . 01-10–29

Removal . . . . . . . . . . . . . . . . . . . . . . . . 01-10–29

Installation

VALVE SPRING INSPECTION . . . . . . . . 01-10–29

CAMSHAFT INSPECTION . . . . . . . . . . . 01-10–30

CYLINDER BLOCK INSPECTION . . . . . 01-10–32

OIL JET VALVE INSPECTION . . . . . . . . 01-10–32

PISTON INSPECTION . . . . . . . . . . . . . . . 01-10–32

PISTON RING INSPECTION . . . . . . . . . . 01-10–33

PISTON PIN INSPECTION . . . . . . . . . . . 01-10–34

PISTON AND CONNECTING ROD

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–35

CONNECTING ROD INSPECTION . . . . . 01-10–35

CONNECTING ROD CLEARANCE

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–35

CRANKSHAFT INSPECTION . . . . . . . . . 01-10–36

DUAL-MASS FLYWHEEL

INSPECTION . . . . . . . . . . . . . . . . . . . . . 01-10–37

Inspection Before Removal . . . . . . . . . 01-10–37

Inspection After Removal . . . . . . . . . . . 01-10–38

PILOT BEARING INSPECTION . . . . . . . 01-10–39

BOLT INSPECTION . . . . . . . . . . . . . . . . . 01-10–39

CYLINDER BLOCK ASSEMBLY (I) . . . . 01-10–40

Thrust Bearing And Main Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–41

Plate Assembly Note . . . . . . . . . . . . . . 01-10–42

Lower Cylinder Block

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–42

. . . . . . . . . . . . . . . . . . . . . . 01-10–29

01-10–1

MECHANICAL

Piston Pin Assembly Note. . . . . . . . . . . 01-10–44

Snap Ring Assembly Note . . . . . . . . . . 01-10–44

Piston Ring Assembly Note. . . . . . . . . . 01-10–45

Connecting Rod Bearing

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–46

Piston, Connecting Rod

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–46

Connecting Rod Cap

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–47

Pilot Bearing Assembly Note . . . . . . . . 01-10–47

CYLINDER BLOCK ASSEMBLY (II) . . . . 01-10–48

Balancer Unit Assembly Note . . . . . . . . 01-10–49

Oil Pump Assembly Note . . . . . . . . . . . 01-10–50

Water Pump Assembly Note . . . . . . . . . 01-10–51

Rear Oil Seal Assembly Note . . . . . . . . 01-10–52

End Plate Assembly Note . . . . . . . . . . . 01-10–53

Dual-mass Flywheel (MTX)/ Drive

Plate (ATX) Installation Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–53

Knock Sensor (KS) Assembly Note . . . 01-10–54

CYLINDER HEAD ASSEMBLY (I) . . . . . . 01-10–55

Valve Seal Assembly Note . . . . . . . . . . 01-10–56

Valve Spring Assembly Note. . . . . . . . . 01-10–56

Valve Keeper Assembly Note . . . . . . . . 01-10–57

Thermostat Assembly Note . . . . . . . . . 01-10–58

CYLINDER HEAD ASSEMBLY (II) . . . . . 01-10–59

Cylinder Head Assembly Note . . . . . . . 01-10–61

Water Inlet Pipe Assembly Note. . . . . . 01-10–62

HLA Assembly Note . . . . . . . . . . . . . . . 01-10–63

Rocker Arm Assembly Note . . . . . . . . . 01-10–63

Camshaft Assembly Note. . . . . . . . . . . 01-10–64

Electric Variable Valve Timing Actuator,

Hydraulic Variable Valve Timing

Actuator Assembly Note. . . . . . . . . . . 01-10–66

TIMING CHAIN ASSEMBLY . . . . . . . . . . 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/

Driver Assembly Note. . . . . . . . . . . . . 01-10–79

Front Oil Seal Assembly Note . . . . . . . 01-10–80

Crankshaft Pulley Lock Bolt

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–80

Water Pump Pulley Assembly Note . . . 01-10–81

Oil Shower Pipe Assembly Note . . . . . 01-10–81

Cylinder Head Cover

Assembly Note . . . . . . . . . . . . . . . . . . 01-10–82

Water Outlet Assembly Note. . . . . . . . . 01-10–57

End of Toc

WM: -

ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER INSPECTION

id011000828100

Caution

• Do not disassemble the electric variable valve timing motor/driver because it is a precision unit.

• Do not apply excessive force when rotating the electric variable valve timing motor joint. If it is

rotated with excessive force, the electric variable valve timing motor could be damaged.

1. Rotate the electric variable valve timing motor joint to the left and right by your fingers and verify that it rotates

smoothly in 15° increments.

Note

• Rotate the joint area smoothly using only the tips of your fingers.

• The electric variable valve timing motor joint moves in 15° increments, and if the joint is moved 24 times, it

rotates one full rotation.

• If it does not rotate smoothly, replace the electric variable valve timing motor/driver.

End Of Sie

WM: VARIABLE VALVE TIMING ACTUATOR

JOINT

ELECTRIC VARIABLE VALVE TIMING MOTOR

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01-10–2

MECHANICAL

HYDRAULIC VARIABLE VALVE TIMING ACTUATOR INSPECTION

Caution

• Do not disassemble the hydraulic variable valve timing actuator because it is a precision unit.

1. Verify that the notch of the rotor and projection of the cover on the hydraulic variable valve timing

PROJECTION

actuator are aligned and fitted.

• If the projection and notch are not aligned, rotate the rotor (camshaft installation) until a click is heard and verify that they are aligned

COVER

and fixed in place. — If the projection and notch are not aligned

or the rotor and cover are not secured even if their projection and notch are aligned, replace the hydraulic variable valve timing actuator.

End Of Sie

ELECTRIC VARIABLE VALVE TIMING ACTUATOR INSPECTION

Caution

• Do not disassemble the electric variable valve timing actuator because it is a precision unit.

1. Rotate the eccentric shaft of the electric variable valve timing actuator to the left and right by hand and verify that it rotates smoothly.

• If it does not rotate smoothly, replace the electric variable valve timing actuator.

JOINT GROOVE

id011000126800

01-10

NOTCH

ROTOR

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Note

ECCENTRIC SHAFT

• Hook a finger onto the joint groove of the eccentric shaft to rotate the shaft easily.

• The eccentric shaft stops rotating at the maximum retard position when it is rotated counterclockwise as viewed from the front, and at the maximum advance position when rotated clockwise.

• The eccentric shaft rotates 15.8 turns from the maximum retard position to the maximum advance position.

End Of Sie

WM: OIL CONTROL VALVE (OCV)

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01-10–3

MECHANICAL

OIL CONTROL VALVE (OCV) INSPECTION

Coil Resistance Inspection

1. Measure the resistance between terminals A and B using an ohmmeter.

OCV coil resistance

6.9—7.5 ohms [20°C {68°F}]

• If it is not within the specification, replace the OCV.

Spool Valve Operation Inspection

1. Verify that the spool valve in the OCV is in the maximum valve timing advance position as indicated in the figure.

• If there is any malfunction, replace the OCV.

Note

• When applying battery positive voltage between the OCV terminals, the connection can be either of the following: — Positive battery cable to terminal A,

negative battery cable to terminal B

— Positive battery cable to terminal B,

negative battery cable to terminal A

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OIL CONTROL VALVE (OCV)

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SPOOL VALVE (MAXIMUM VALVE TIMING ADVANCE POSITION)

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2. Apply battery positive voltage between the OCV terminals and verify that the spool valve operates and moves to the maximum valve timing retard position.

• If there is any malfunction, replace the OCV.

3. Stop applying battery positive voltage and verify that the spool valve returns to the maximum valve timing advance position.

• If there is any malfunction, replace the OCV.

End Of Sie

WM: HYDRAULIC LASH ADJUSTER (HLA)

OIL CONTROL VALVE (OCV)

VALVE TIMING RETARD

SPOOL VALVE (MAXIMUM VALVE TIMING RETARD POSITION)

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VALVE TIMING ADVANCE

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01-10–4

MECHANICAL

HYDRAULIC LASH ADJUSTER (HLA) INSPECTION

1. Visually inspect the HLA surface where it contacts the rocker arm for wear or damage.

• If there is any malfunction, replace the HLA.

End Of Sie

WM: ROCKER ARM

ROCKER ARM INSPECTION

1. Rotate the roller or the rocker arm by hand and verify that rotates smoothly.

• 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 rocker arm.

End Of Sie

EN: ENGINE COMPLETE

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ROCKER ARM CONTACT SURFACE

01-10

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ROLLER

ENGINE OVERHAUL SERVICE WARNING

Warning

• Continuous exposure to USED engine oil has been shown to cause skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after performing work.

End Of Sie

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01-10–5

MECHANICAL

ENGINE MOUNTING/DISMOUNTING

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Mounting

1. Install the SST (arms) to the three positions as shown in the figure and temporarily tighten the bolts (Part No. 9YA20-1003 or M10 × 1.5 length 90 mm {3.55 in}).

SST INSTALLATION HOLE

ENGINE FRONT

SST INSTALLED

49 L010 102

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2. Install the SSTs (bolts and nuts) to the three positions of the SST (plate) as shown in the figure.

49 L010 101

49 L010 104

3. Install the SST (bolts, nuts and plate) set in Step 2 to the SST (arms) set in Step 1 using the SSTs (hook and nuts).

4. Adjust the bolts so that approx. 20 mm {0.79 in} of thread is exposed 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 stand).

8. Remove the oil drain plug and drain the engine oil.

9. Replace the gasket with a new one and install the oil pan drain plug.

Tightening torque

30—41 N·m {3.1—4.1 kgf·m, 23—30 ft·lbf}

Dismounting

1. Dismount in the reverse order of mounting.

End Of Sie

49 L010 102

49 L010 104

ENGINE

PARALLEL

49 L010 103

49 L010 105

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49 L010 101

49 L010 104

49 L010 105

APPROX. 20 mm {0.79 in}

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01-10–6

MECHANICAL

TIMING CHAIN DISASSEMBLY

Caution

• If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and 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 the cast hexagon, the wrench may contact the rocker arm and damage

CAMSHAFT

WRENCH

CAST HEXAGON

the rocker arm. To prevent damage to the rocker arm when holding the camshaft on the cast hexagon, use a wrench on the rear side of the engine as shown in the figure to secure a clearance between the cam.

ROCKER ARM CONTACT

SECURE CLEARANCE

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01-10

ENGINE REAR

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

CAMSHAFT

DOES NOT CONTACT

CAST HEXAGON

22—24 mm {0.87

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—0.94 in}

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01-10–7

MECHANICAL

1. Disassemble in the order indicated in the table.

SST

SST SST

1 Dipstick 2 Cylinder head cover 3 Oil shower pipe

01-10–8

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4 Spark plug 5 Water pump pulley

(See 01-10-9 Water Pump Pulley Disassembly Note.)

MECHANICAL

6 Crankshaft pulley lock bolt

(See 01-10-10 Crankshaft Pulley Lock Bolt

Disassembly Note.) 7 Crankshaft pulley 8 Electric variable valve timing motor/driver 9Oil pan

(See 01-10-10 Oil Pan Disassembly Note.)

10 Engine front cover

(See 01-10-10 Engine Front Cover Disassembly

Note.)

11 Front oil seal

(See 01-10-11 Front Oil Seal Disassembly Note.)

12 Chain guide (No.1) 13 Chain tensioner

(See 01-10-11 Chain Tensioner Disassembly Note.)

14 Tensioner arm

15 Timing chain 16 Chain guide (No.2) 17 Crankshaft sprocket 18 Oil pump chain tensioner

(See 01-10-12 Oil Pump Chain Disassembly Note.)

19 Balancer shaft sprocket

(See 01-10-12 Oil Pump Chain Disassembly Note.)

20 Oil pump chain

(See 01-10-12 Oil Pump Chain Disassembly Note.)

21 Oil pump driven sprocket

(See 01-10-12 Oil Pump Chain Disassembly Note.) 22 Oil pump chain guide 23 Oil pump drive sprocket 24 Key

Water Pump Pulley Disassembly Note

Caution

• Be careful not to damage the belt groove and surface of the water pump pulley when using tools, otherwise it will cause wear, breakage, abnormal noise of the drive belt (stretch belt), damage to the pulley, and rust.

1. Align the water pump pulley hole with the water pump hole as shown in the figure.

WATER PUMP

HOLEHOLE

01-10

2. Insert an appropriate bolt (length approx. 70 mm {2.8 in}) into the water pump hole as shown in the

figure, and lock the water pump pulley against rotation.

3. Remove the water pump pulley.

4. Remove the bolt used for locking the water pump pulley against rotation.

WATER PUMP PULLEY

am3uuw00008841

WATER PUMP PULLEY

BOLT

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01-10–9

MECHANICAL

Crankshaft Pulley Lock Bolt Disassembly Note

1. Hold the crankshaft using the SST.

2. Remove the crankshaft pulley lock bolt.

Oil Pan Disassembly Note

1. Remove the oil pan using a separator tool.

49 E011 1A0

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Engine Front Cover Disassembly Note

1. Remove the engine front cover installation bolts.

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 to the screwdriver. Otherwise, the engine front cover could be damaged.

• Be careful not to scratch or damage the seal surface. Otherwise, it could cause oil leakage.

CLOTH

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CLOTH

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01-10–10

CLOTH

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MECHANICAL

Front Oil Seal Disassembly Note

1. Remove the oil seal using a flathead screwdriver with the tip protected by a clean cloth.

Chain Tensioner Disassembly Note

1. While moving the exhaust camshaft back and forth in the direction of the arrow using a wrench on the cast hexagon, press down the link plate of the timing chain tensioner using a precision screwdriver and release the plunger lock.

CLOTH

01-10

FRONT OIL SEAL

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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. Push back the plunger slowly in the direction shown in the figure with the link plate still pushed down.

3. Remove the screwdriver from the link plate with the plunger still pushed down.

4. Release the force slightly from the plunger, and move it back and forth 2—3 mm {0.08—0.11 in}.

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LINK PLATE

PLUNGER

am3uuw00008854

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01-10–11

MECHANICAL

5. Insert a wire with an approx. diameter of 1.5 mm {0.059 in} or a paper clip where the link plate hole

and the tensioner body hole overlap to secure the link plate and lock the plunger.

6. Remove the chain tensioner.

WIRE OR PAPER CLIP

LINK PLATE

TENSIONER BODY HOLE

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Oil Pump Chain Disassembly Note

1. Hold the crankshaft using the SST.

2. Slightly loosen 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 tensioner.

3. Set a cloth wrapped flathead screwdriver in the gap between the oil pump drive sprocket and the oil pump chain as shown in the figure.

OIL PUMP DRIVE SPROCKET

49 E011 1A0

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OIL PUMP CHAIN TENSIONER

01-10–12

OIL PUMP CHAIN

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MECHANICAL

4. Move the screwdriver in the direction of the arrow and press the oil pump chain, and then press on the plunger of the oil pump chain tensioner.

OIL PUMP CHAIN

OIL PUMP DRIVE SPROCKET

OIL PUMP CHAIN TENSIONER

01-10

BEFORE PRESSING AFTER PRESSING

PLUNGER

OIL PUMP CHAIN TENSIONER

5. Insert a wire with an approx. diameter of 1.4 mm {0.055 in} or a paper clip into the body hole of the oil pump chain tensioner with the plunger pressed.

OIL PUMP CHAIN TENSIONER

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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 shaft sprocket as a single unit.

8. Remove the oil pump driven sprocket.

End Of Sie

WIRE OR PAPER CLIP

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01-10–13

MECHANICAL

CYLINDER HEAD DISASSEMBLY (I)

Caution

• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage

CAMSHAFT

WRENCH

CAST HEXAGON

ROCKER ARM CONTACT

SECURE CLEARANCE

id011000500400

ENGINE REAR

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

CAMSHAFT

DOES NOT CONTACT

CAST HEXAGON

22—24 mm {0.87

am3uuw00008837

—0.94 in}

am3uuw00009029

01-10–14

MECHANICAL

1. Disassemble in the order indicated in the table.

01-10

WITHOUT OIL COOLER

WATER PUMP

WITH OIL COOLER

1 Electric variable valve timing actuator, hydraulic

variable valve timing actuator (See 01-10-16 Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator

Disassembly Note.) 2OCV 3 Camshaft cap

(See 01-10-16 Camshaft Cap Disassembly Note.) 4 Camshaft

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5 OCV oil filter 6 Rocker arm

(See 01-10-16 Rocker Arm Disassembly Note.)

7HLA

(See 01-10-16 HLA Disassembly Note.) 8 Water inlet pipe 9 Cylinder head

(See 01-10-16 Cylinder Head Disassembly Note.)

10 Cylinder head gasket

01-10–15

MECHANICAL

Electric Variable Valve Timing Actuator, Hydraulic Variable Valve Timing Actuator Disassembly Note

1. Hold the camshaft using a wrench on the cast hexagon and loosen the actuator installation bolt.

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Camshaft Cap Disassembly Note

1. Before removing the camshaft cap, Inspect the camshaft end play. (See 01-10-30 CAMSHAFT INSPECTION.)

2. Loosen the camshaft cap installation bolts in two or three passes in the order shown in the figure and remove the camshaft caps.

4 3

Rocker Arm Disassembly Note

1. Keep the rocker arms in the order of removal to enable reassembly in their original positions.

HLA Disassembly Note

1. Keep the HLAs in the order of removal to enable reassembly in their original positions.

Cylinder Head Disassembly Note

1. Loosen the cylinder head installation bolts in two or three passes in the order shown in the figure

and remove them.

End Of Sie

ENGINE FRONT

am3uuw00008985

159

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01-10–16

MECHANICAL

CYLINDER HEAD DISASSEMBLY (II)

1. Disassemble in the order indicated in the table.

SST

id011000500500

01-10

1 Thermostat cover 2 Thermostat 3 Water outlet 4 Valve keeper

(See 01-10-18 Valve Keeper Disassembly Note.)

5 Upper valve spring seat

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6Valve spring 7Valve 8 Valve seal

(See 01-10-18 Valve Seal Disassembly Note.)

9 Lower valve spring seat

01-10–17

+ 71 hidden pages

Mazda SKYACTIV-G 2.5 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual