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Mazda CX-5 Service & Repair Manual: Timing Chain Removal/Installation

Mazda CX-5 Service & Repair Manual / Engine / Belts, Hoses, Pulleys / Timing Chain Removal/Installation

WARNING:

CAUTION:

NOTE:

1. Disconnect the negative battery cable..

2. Remove the plug hole plate..

3. Remove the ignition coil/ion sensors..

4. Remove the front under cover No.2..

5. Remove the splash shield..

6. Remove the drive belt..

7. Drain the engine oil..

8. Remove the oil pan..

9. Remove in the order indicated in the table.

10. Install in the reverse order of removal.

11. Refill with the specified type and amount of the engine oil..

12. Start the engine and inspect the following:



1

Dipstick

2

Cylinder head cover

(See Cylinder Head Cover Removal Note.)

(See Cylinder Head Cover Installation Note.)

3

Oil shower pipe

(See Oil Shower Pipe Installation Note.)

4

Drive belt auto tensioner

(See Drive Belt Auto Tensioner Installation Note.)

5

Water pump pulley

(See Water Pump Pulley Removal Note.)

(See Water Pump Pulley Installation Note.)

6

Crankshaft pulley lock bolt

(See Crankshaft Pulley Lock Bolt Removal Note.)

(See Crankshaft Pulley Lock Bolt Installation Note.)

7

Crankshaft pulley

8

Front oil seal

(See FRONT OIL SEAL REPLACEMENT [SKYACTIV-G 2.0].)

9

No.3 engine mount

(See No.3 Engine Mount Removal Note.)

(See No.3 Engine Mount Installation Note.)

10

Electric variable valve timing motor/driver

(See Electric Variable Valve Timing Motor/Driver Installation Note.)

11

Engine front cover

(See Engine Front Cover Removal Note.)

(See Engine Front Cover Installation Note.)

12

Chain tensioner

(See Timing Chain Removal Note.)

(See Timing Chain Installation Note.)

13

Tensioner arm

(See Timing Chain Removal Note.)

(See Timing Chain Installation Note.)

14

Chain guide (No.1)

(See Timing Chain Removal Note.)

(See Timing Chain Installation Note.)

15

Timing chain

(See Timing Chain Removal Note.)

(See Timing Chain Installation Note.)

16

Chain guide (No.2)

17

Crankshaft sprocket

18

Oil pump chain tensioner

19

Oil pump driven sprocket

(See Oil Pump Driven Sprocket Removal Note.)

(See Oil Pump Driven Sprocket Installation Note.)

20

Oil pump chain

21

Oil pump drive sprocket

22

Key


Cylinder Head Cover Removal Note

1. Disconnect the OCV connector.

2. Remove the wiring harness clips secured to the cylinder head cover.

3. Remove the wiring harness clip secured to the intake manifold as shown in the figure, and set the wiring harness aside.


4. Disconnect the ventilation hose.

5. Disconnect the brake vacuum hose from the intake manifold and set it aside.

6. Remove the cylinder head cover.

Water Pump Pulley Removal Note

CAUTION:

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


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.

Crankshaft Pulley Lock Bolt Removal Note

CAUTION:

1. Install the SST

to the crankshaft pulley, and lock the crankshaft against rotation.


2. Remove the crankshaft pulley lock bolt.

No.3 Engine Mount Removal Note

1. Remove the clips shown in the figure and set the ground cable aside.


2. Install the SST

using part number 99794 1025

or an M10 ? 1.25

, length 25 mm {0.98 in}

bolt as shown in the figure.


CAUTION:

3. Place alignment marks on the locations shown in the figure so that they can be assembled to the same positions as before removal.


NOTE:

4. Install the SST

using the following procedures.

CAUTION:

NOTE:


a. Protect the positions shown in the figure using tape.


b. As shown in the figure, set the rear shafts of the SST

to the left and right shock absorber nuts.


c. As shown in the figure, set the front shafts of the SST to the left and right bolts.


d. Adjust the height of the left and right side bars of the SST

so that they are leveled, then tighten each part.


e. Apply tension to the chain to hold the engine.

5. Remove the No.3 engine mount.

Engine Front Cover Removal Note

1. Remove the insulator shown in the figure.


2. Set the ground cable and wiring harness bracket shown in the figure aside.


3. Remove the engine front cover installation bolts.

4. Using a screwdriver wrapped in a cloth, peel the sealant away a little at a time, and remove the engine front cover.

CAUTION:



Timing Chain Removal Note

1. Rotate the crankshaft clockwise to align the timing marks and the key position as shown in the figure, and set cylinder No.1 at top dead center (TDC).


2. 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.



NOTE:

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


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

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

.

6. 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.


7. Remove the chain tensioner, tensioner arm, and the chain guide (No.1).

8. Remove the timing chain.

Oil Pump Driven Sprocket Removal Note

1. Temporarily assemble the crankshaft pulley lock bolt, and lock the oil pump against rotation as shown in the figure.


2. Remove the oil pump driven sprocket.

3. Remove the temporarily assembled crankshaft pulley lock bolt.

Oil Pump Driven Sprocket Installation Note

1. Temporarily assemble the crankshaft pulley lock bolt, and lock the oil pump against rotation as shown in the figure.


2. Install the oil pump driven sprocket.

3. Remove the temporarily assembled crankshaft pulley lock bolt.

Timing Chain Installation Note

1. Verify that the timing marks and the key are aligned to the position shown in the figure.


2. Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure.


3. Install the chain guide (No.1).

4. Install the tensioner arm.

5. Install the chain tensioner.

6. After installing the chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing chain.

7. Verify that there is no looseness in the timing chain, and re-verify that each sprocket is in the specified location.

8. Rotate the crankshaft clockwise two turns and inspect the valve timing.


Engine Front Cover Installation Note

NOTE:

1. If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.


2. Remove oil, dirt, and sealant adhering to the engine front cover, cylinder head, and cylinder block.

3. When reusing an engine front cover installation bolts, remove sealant adhering to the bolts.

CAUTION:

4. Apply silicone sealant to the engine front cover as shown in the figure.


5. Apply silicone sealant to the areas shown in the figure.


CAUTION:

6. Install the engine front cover to the engine.

NOTE:


7. Prepare an appropriate M8 X 1.25

bolt (length 40 mm {1.6 in}

).

8. Tighten the engine front cover installation bolts in the order shown in the figure.


9. Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.

10. Install the ground cable and wiring harness bracket shown in the figure.


Electric Variable Valve Timing Motor/Driver Installation Note

1. Install a new O-ring to the O-ring installation groove of the engine front cover.

CAUTION:


2. Install the electric variable valve timing motor/driver using the following procedures.

NOTE:

a. Before installation, rotate the joint of the end of the electric variable valve timing motor so that it is aligned to the joint groove on the electric variable valve timing actuator side.


b. Engage the joint on the end of the electric variable valve timing motor with the joint groove on the electric variable valve timing actuator side.

c. Attach the seal surface.

d. Tighten the electric variable valve timing motor/driver installation bolts.

No.3 Engine Mount Installation Note

CAUTION:

NOTE:

1. Tighten the No.3 engine mount stud bolts.


2. Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:

a. Align the alignment marks on the body side and No.3 engine mount, and temporarily tighten the bolts shown in the figure.


b. Temporarily tighten the nuts shown in the figure while aligning the alignment marks of the No.3 engine mount and nuts.


NOTE:

3. Tighten the No.3 engine mount installation bolts and nuts in the order as shown in the figure.



No.

Tightening torque

1

76—95 N·m {7.8—9.6 kgf·m, 57—70 ft·lbf}

2

82—95 N·m {8.4—9.6 kgf·m, 61—70 ft·lbf}

3

49—65 N·m {5.0—6.6 kgf·m, 37—47 ft·lbf}


4. Remove the SST

.

5. Install the clip of ground cable to the No.3 engine mount.

Crankshaft Pulley Lock Bolt Installation Note

CAUTION:

1. Install the SST

on the crankshaft pulley to lock the crankshaft against rotation.


2. Tighten the crankshaft pulley lock bolt in the order shown in the following two steps.

Water Pump Pulley Installation Note

CAUTION:

1. Install the water pump pulley to the water pump and temporarily tighten the bolt.

2. Align the water pump pulley hole with the water 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 the water pump pulley bolt to the specified torque.

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

Drive Belt Auto Tensioner Installation Note

CAUTION:

1. Install the drive belt auto tensioner to the engine.

CAUTION:

2. Insert the wrench into the cast hexagon on the drive belt auto tensioner, move the drive belt auto tensioner up and down at full-stroke three times to bleed the air.


NOTE:

Oil Shower Pipe Installation Note

1. Install the oil shower pipe in the order shown in the figure.


Tightening torque

Installation position

Tightening torque

1

9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

2, 3

8.0—9.0 N·m {82—91 kgf·cm, 71—79 in·lbf}


Cylinder Head Cover Installation Note

CAUTION:

1. Insert a new cylinder head cover gasket into the cylinder head cover groove.

2. Apply silicone sealant to the areas shown in the figure.


3. Tighten the cylinder cover bolts in the order shown in the figure.


Rear Center Seat Belt Removal/Installation
CAUTION: The ELR (emergency locking retractor) has a spring that will unwind if the retractor cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not wor ...

Timing Chain, Chain Tensioner
Purpose, Function Timing chain The timing chain transmits the rotation force of the crankshaft to the camshaft to perform the rotation timing of the crankshaft and camshaft. Chain ten ...

Other materials:

Engine Oil Replacement
WARNING: 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 ...

Intake Manifold
Purpose, Function Distributes intake air to each cylinder evenly. Optimizes the combustion efficiency and performance of the engine by distributing intake air to each cylinder. Construction The intake manifold is installed to the cylinder head. ...

Oil Seal (Coupling Component) Replacement
1. Drain the differential oil into a container. 2. Remove the coupling component.. 3. Remove the oil seal from the differential carrier using a screwdriver or similar tool. 4. Apply differential oil to the new oil seal lip. 5. Install the new oil seal to the differential carrier using the ...

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