Repair Procedure
REPAIR PROCEDUREWARNING:
^ Hot engines and engine oil can cause severe burns. Turn off the engine and wait until it and the engine oil have cooled.
^ A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands.
^ Continuous exposure to USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after working with engine oil.
Removal
1. Write down the customer's radio station presets.
2. Install fender cover to avoid damage on the fenders.
3. Disconnect the battery cables.
4. Remove the engine cover (A), fresh air duct (F), the air cleaner assembly (E), the air hose (B), the battery (C) and the battery tray (D) from the engine compartment.
5. Remove the harness bracket (A).
6. Remove the air duct (A).
a. Disconnect the purge solenoid valve connector.
b. Disconnect the EGR valve connector.
c. Move ATF gauge pipe (B) out of the way.
7. Loosen the bolts of the water pipe (A) brackets (B and C).
8. Remove the under cover and right side splash shield
9. Drain the engine oil into a container.
10. Install the oil pan drain plug with a new washer.
Tightening Torque: 30-41 N.m (3.1-4.1 kgf-m, 23-30 ft-lb)
11. Before loosening the bolts securing the engine and transmission, put a mark on each transaxle bolt and the transaxle (so you can determine when they have been turned one full turn), then loosen the bolts one full turn (360 degrees).
NOTE:
Loosen the bolts from the top of the transaxle to the bottom.
CAUTION:
DO NOT loosen the bolts more than one turn (360 degrees), or the transaxle may get damaged.
Letters shown in the illustration above are for orientation of the block diagram only.
12. Remove the four bolts that secure the front cover to the oil pan.
13. Remove the dipstick pipe and bolts.
Oil Pan Removal Note
Remove the oil pan using a separator tool.
Installation
NOTE:
The thickness of silicone sealant tends to be thin because the clearance between the oil pan and the transmission and the front cover and transmission is almost zero during oil pan reinstallation. Allow 3 mm space maximum between the engine and transmission with the transaxle bolts loosened one full turn before reinstalling the oil pan.
Letters in the illustration above is for orientation of the block diagram only.
1. Clean the location where silicone sealant will be applied.
2. Using a scraper or a similar tool, completely remove the gasket residue from the joint of cylinder block, front cover and oil pan.
NOTE:
Do not allow the gasket residue to enter the oil pan. Using cleaning fluid, completely remove the oil from the joint. Especially be sure to completely remove oil and gasket residue from the corner section of the front cover and the cylinder block.
Recommended Cleaner:
- Mazda Brake Parts Cleaner (low VOC, non-chlorinated) P/N 000-77-620E-05 or equivalent.
3. Completely clean and remove any oil, dirt, sealant or other foreign material that may be adhering to the housing and oil pan.
CAUTION:
When reusing oil pan installation bolts, clean any old sealant from the bolts. Using bolts with the old seal adhering could cause cracks in the housing.
4. Apply silicone sealant to the oil pan in a single, unbroken line around the whole perimeter of the oil pan as shown in the following illustrations.
NOTE:
Install the oil pan within 10 minutes after applying the silicone sealant, otherwise the gasket material will get too hard and you will have to scrape the oil pan clean and apply silicone sealant again.
a. Apply a 2.5 mm bead down the center of the sides of the oil pan (A).
b. Apply a 2.5 mm bead to the rear edge (B) of the oil pan (approximately 5mm from the rear edge).
c. Apply inside the bolt holes (C).
d. Apply silicone sealant to the front edge of the oil pan and to the front cover where the two pieces attach together.
e. Apply an ample amount to the front cover where the oil pan is fitted (A), and also apply an extra amount (a ball of approximately 5 mm in diameter) of silicone sealant to the corners of the front case and the cylinder block (B).
5. Install the oil pan on the cylinder block.
6. Install and tighten the oil pan bolts and front cover bolts as follows. The front of the engine is (F) and the rear of the engine is (R).
a. Install and tighten all oil pan bolts and the four front cover bolts 2 or 3 turns.
b. Install the front cover stud bolt directly under the crank pulley lock bolt.
c. Tighten the No. 6, No. 7, No. 8 and No. 9 oil pan bolts to 17.0-23.0 N.m (12.5-17 ft-lb).
d. Then loosen the No. 6, No. 7, No. 8 and No. 9 oil pan bolts by turning counterclockwise 180 degrees.
e. Tighten the 4 front cover bolts to 8.0-11.5 N.m (5.9-8.5 ft-lb) in the order shown above.
f. Tighten the 13 oil pan bolts to 17.0-23.0 N.m (12.5-17 ft-lb) in the order shown above.
7. Tighten all the bolts securing the engine and transaxle.
NOTE: Tighten the bolts from the bottom of the transaxle to the top of the
transaxle.
Letters shown in the illustration above is for orientation of the block diagram only.
Tightening torque: 37 - 52 N.m (27.5-38.3 ft-lb)
Special Bolt - Tightening torque: 25.5 - 34.5 N.m (18.9-25.4 ft-lb)
8. Install the right side splash shield.
9. Tighten the bolts of the water pipe (A) brackets (B and C).
10. Install the air duct (A) and ATF gauge pipe (B).
11. Install the harness bracket.
12. Install the battery tray (D), battery (C), and the air hose (B) the air cleaner assembly (E) the fresh air duct (F) and engine cover (A).
13. Add engine oil.
NOTE:
Make sure that the oil filler cap is fitted properly.
14. Connect the battery cables.
15. Start the engine and let it reach normal operating temperature, then inspect for oil leakage around the oil pan.
16. Stop the engine and wait for 5 minutes, then check the oil level using the oil level gauge. If it is not adequate, add more oil.
17. Install the under cover.
18. Re-enter the customer's radio station presets.