Mazda Engine SKYACTIV-G 2.5. Manual — part 4

01-10–1

01

ENGINE

SECTION

01-10

Toc of SCT

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

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

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

Toc of SCT

01-10

MECHANICAL

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

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

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

MECHANICAL

01-10–2

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

Water Outlet 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

End of Toc

WM: -

ELECTRIC VARIABLE VALVE TIMING MOTOR/DRIVER INSPECTION

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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

ELECTRIC VARIABLE VALVE TIMING MOTOR

JOINT

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MECHANICAL

01-10–3

01-10

HYDRAULIC VARIABLE VALVE TIMING ACTUATOR INSPECTION

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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

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

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

id011000555500

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.

Note

• 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)

ROTOR

NOTCH

COVER

PROJECTION

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JOINT GROOVE

ECCENTRIC SHAFT

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