Removal and installation the timing chain (Mazda CX-5KE)

Note:
: replace the part with a new one after each removal.
: use a special tool or device.
: places where sealant is applied.
: apply oil.

Attention.

• A hot engine can cause burns. Before starting work, turn off the engine and wait until it cools down.
• When turning the camshaft with a wrench on the hexagonal part, the wrench may hit the rocker arm and damage it. To prevent damage to the rocker arm, when holding the camshaft by the hexagonal part, place the wrench closer to the rear of the engine, as shown in the figure, to ensure a safe gap between the wrench and the camshaft lobe.

Note: The width of the hexagonal part of the camshaft is 22-24mm.

Removal

1. Disconnect the negative battery terminal.

2. Remove the decorative engine cover.

3. Remove the front protective tray No.2.

4. Remove the mudguard.

5. Remove the accessory drive belts.

6. Drain the engine oil.

7. Remove the oil pan.

8. Remove the fuel injectors from the engine.

9. Drain the coolant.

10. Remove the insulating casing from the engine.

11. Remove the oil dipstick.

12. Remove the fuel pressure line.

13. Remove the high pressure fuel lines (from the pump feed side).

14. Move the electrical wiring aside:

Remove the engine decorative cover adapter and unscrew the nuts shown in the figure.



Disconnect the connectors and clamps shown in the figure.



Remove the clamps shown in the picture and move the wires aside.





Move the ground cable clamp shown in the illustration away from the cylinder head cover.



15. Move the lower housing with the fuel hose bracket to the side:

Disconnect the vacuum hose from the vacuum pump.



Disconnect return fuel hose No.4 from the fuel rail.

Loosen the bolts and nut securing the fuel hose bracket without disconnecting the main hose and return hose No.1.



Remove the lower housing with the main fuel hose and return hose No.1 and set aside.

16. Remove the bracket for exhaust gas pressure sensor No.1.



17. Remove the cylinder head cover.

18. Loosen the mounting bolts and remove the oil spray pipe from the cylinder head.

19. Loosen the central bolt and remove the crankshaft pulley.

20. Remove the front crankshaft oil seal from the front engine cover.

21. Remove the clamp and unscrew the bolt shown in the figure, then move the ground cable to the side.



22. Loosen the bolts and disconnect the connector shown in the figure, then move the electronic engine control unit to the side without disconnecting the connector from it.



23. Move the connector and coolant hose shown in the figure to the side and remove the wiring harness bracket.





24. Remove the engine decorative cover adapter shown in the figure.



25. Using the bolt and washer, install the lifting eye onto the engine as shown in the figure.

Note:

• Bolt: catalog number 99794 1025 or M10x1.25, 25 mm long.
• Washer: thickness approximately 3mm.
• Tightening torque: 38-51 Nm.

26. Using the bolt and washer, install the second lifting eye onto the engine as shown in the figure.

Note:

• Bolt: catalog number 99794 1025 or M10x1.25, 25 mm long.
• Washer: thickness approximately 3mm.
• Tightening torque: 38-51 Nm.

Caution: The grooves must match the installation holes of the engine mounting support No.3. If the position of the engine mounting support No.3 is different from the original position when reinstalled, this will lead to increased engine noise and vibration. Before removing the engine mounting support No.3, apply installation marks to the engine mounting support No.3 so that the support can be installed in the same position later.

27. Apply alignment marks to the locations shown in the figure so that the engine mount can be installed in the same position later.

Note: Trace around engine mount #3 and mounting nuts as shown.

28. Install the crossmember for hanging the engine 49 C017 5A0:

Attention: Follow the instructions supplied with the crossbar by the manufacturer.

Note: Install front legs #2 on the left and right support rods of the crossbar.

Protect the areas shown in the figure with electrical tape.



Place the rear crossmember support rods onto the left and right suspension strut nuts as shown.



Install the front crossmember rods onto the bolts on the left and right as shown in the figure.





Adjust the height of the left and right side beams of the cross member so that they are level, and then tighten all parts.



Install the hanging bracket (49 L017 5A0) on the traverse (49 UN30 3050), directing the hooks of the hanging bracket outward.



Adjust the height of the left and right side beams of the cross member so that they are level, and then tighten all parts.

Tighten the chain connecting the crossmember to the engine.

29. Remove engine support No.3.

30. Remove the automatic tensioner of the accessory drive belt (see the relevant section above in this chapter).

31. Loosen the mounting bolt and remove the cooling system pipe with the hose connected, then set it aside.

Note: : replace the part with a new one after each removal.

32. Remove the soundproofing covers (Nos. 1 and 2) with rubber gaskets in the sequence shown in the figure.



33. Disconnect the connectors shown in the figure and move the wires to the side.



34. Loosen the cooling system pipe mounting bolt shown in the figure.



35. Disconnect the connectors and clamps, unscrew the bolts shown in the figure, then move the wires and wiring bracket to the side.



36. Remove rubber seal No.3 shown in the figure.



37. Loosen the mounting bolts and, using a screwdriver wrapped in a rag, gradually separate the sealant, then remove the front engine cover.

Attention.

• Do not apply excessive force to the screwdriver. Otherwise, the front cover of the engine may be damaged.
• Be careful not to scratch or damage the contact surfaces, otherwise this may cause oil leaks.

38. Turn the crankshaft clockwise to set the timing marks and crankshaft key to the position shown in the figure (the top dead center (TDC) position of the piston of the first cylinder).



39. Loosen the timing chain tensioner as follows:

Insert a wire with a diameter of approximately 1.4 mm or a rolled up piece of paper into the hole in the timing chain tensioner housing.



While moving the exhaust camshaft with an Allen key in the direction of the arrow in the figure, press the plunger of the timing chain tensioner.

Note: Turning the exhaust camshaft clockwise tightens the drive chain slightly, causing the tensioner plunger to be pressed in.

With the plunger pressed in, thread the wire or rolled up paper previously inserted into the tensioner body even further.

Note: The wire or rolled up paper will hold the plunger in place, which will take the tension off the drive chain.

40. Remove the drive chain tensioner with the tensioner shoe.

41. Remove the timing chain tensioner.

42. Remove the timing chain.

43. Remove the sprocket from the crankshaft.

44. Make sure that the timing marks of the oil pump drive sprockets and the key are in the positions shown in the figure.

Note: If the position of the timing marks and key differs from those shown in the figure, turn the crankshaft one more revolution and set the piston of the first cylinder No.1 to the top dead center (TDC) position.

45. Temporarily tighten the crankshaft pulley bolt and hold the oil pump from turning as shown in the figure.



46. Loosen the oil pump sprocket mounting bolt.

Note: At this stage, you only need to loosen the sprocket mounting bolt, but do not unscrew it completely. Unscrew the bolt after removing the oil pump drive chain tensioner.

47. Insert a flat-head screwdriver wrapped in cloth into the gap between the protrusion at the bottom of the cylinder block and the oil pump chain, as shown in the figure.



48.Moving the screwdriver in the direction of the arrow, press the oil pump drive chain and press the plunger of the oil pump drive chain tensioner.



49. Press the plunger and insert a wire with a diameter of approximately 1.4 mm or a rolled-up piece of paper into the hole in the oil pump chain tensioner housing.

Note: The wire or rolled up paper will hold the plunger in place, which will take the tension off the drive chain.

50. Remove the oil pump chain tensioner.

51. Remove the drive chain with the oil pump sprocket as one unit.

52. Unscrew the temporarily installed crankshaft pulley bolt.

53. Remove the key from the crankshaft.

Installation

1. Installation is carried out in the reverse order of removal, taking into account the following:

Installing the oil pump drive chain

Make sure that the crankshaft key and dowel pin are positioned as shown in the figure. If the position of these elements is different from that shown in the figure, turn the crankshaft one more revolution to set the piston of the first cylinder to the top dead center position.

Note: To rotate balance shaft No.1, temporarily install the oil pump sprocket, then rotate while holding the sprocket with your hand.

Align the timing marks on the drive chain with the marks on the oil pump sprocket.



Install the drive chain with the oil pump sprocket as one unit, aligning the timing marks on the sprockets and drive chain as shown in the figure.



Tighten the oil pump sprocket mounting bolt.

Install the oil pump drive chain tensioner.

Caution: Do not remove the wire or rolled paper inserted into the tensioner housing at this stage.

Install the crankshaft pulley and temporarily screw in the central bolt, then install the special tool shown in the figure to lock the oil pump from turning. Tighten the oil pump sprocket mounting bolt to 123-140 Nm.



Remove the temporarily installed central bolt and pulley from the crankshaft. Remove the wire or rolled up paper inserted into the hole in the oil pump housing.

Note: If a new timing chain tensioner is used, remove the installed retainer.

Installing the timing chain

Make sure that the timing marks and the crankshaft key are positioned as shown in the figure. If the timing marks are not positioned as shown, turn the camshaft and crankshaft until the piston of the first cylinder is set to the top dead center (TDC) position.



Install the timing chain by aligning the sprocket and drive chain marks as shown in the figure.



Install the drive chain tensioner.

Install the timing chain tensioner shoe.

Install the timing chain tensioner.

After installing the tensioner, remove the wire or rolled up paper inserted into it, and then create tension on the drive chain.

Note: If a new timing chain tensioner is used, remove the installed retainer.

Make sure there is no slack in the timing chain and recheck the position of the timing marks on all sprockets.

Turn the crankshaft two turns clockwise and check the position of all timing marks again.

Installing the front engine cover

Note: For the new engine front cover, the two dowel pins shown in the picture are protruding from the outside of the engine. Therefore, it is necessary to tap these dowel pins in with a hammer.

Remove oil, dirt and sealant residue from the mating surfaces of the front engine cover, cylinder head and cylinder block.

When reusing the front engine cover mounting bolts, remove any remaining fixing compound from their threads.

Attention.

• Apply silicone sealant in an even, continuous strip.
• To prevent premature hardening of the silicone sealant, install the front cover on the engine within 10 minutes after applying the sealant. Tighten the mounting bolts immediately.
• Tightening a bolt with cured sealant may cause a crack in the cylinder head or cylinder block.

Apply silicone sealant as shown in the picture.



Apply sealant also to the areas shown in the following figure.

Caution: Apply silicone sealant so that it enters the cylinder head gasket.

Install the front engine cover onto the engine.

Tighten the front engine cover mounting bolts in the sequence shown in the figure to the specified tightening torques.

Note:

Tightening torques:

• Bolts 1... 19: 20-26 Nm.
• Bolts 20...22: 40-55 Nm.

Attention: Bolts 1 and 8 (see numbering in the figure), are installed with washers.

Installation of soundproof covers (No. 1 and 2) with rubber seals

Place rubber seal #3 on the front engine cover.



Install the electrical wiring and harness bracket.

Note: Rubber seal No.3 is fixed by installing the wiring bracket.

Tighten the cooling system hose mounting bolt.

Connect the connectors of exhaust gas temperature sensor No.3 and the air-fuel mixture sensor.

Caution: Make sure that the covers and rubber seals are not pinched by the sound insulation mounting bolts.

(For details, see the website: mazbook)

Install the soundproofing caps and rubber seals in the sequence shown in the figure.

Installing the cooling system hose

Attention.

• Do not apply too little (engine, transmission, etc.) on the O-rings of the water inlet pipe. Otherwise, the O-ring material may be damaged, which will lead to a loss of tightness.
• Install the cooling system hose so as not to damage the O-ring. Otherwise, the seal will be broken, which will lead to leaks.

Apply cooling liquid to the O-ring.

Note: : replace the part with a new one after each removal.

Install the cooling system hose.

Installing an automatic drive belt tensioner

Caution: To ensure proper operation of the automatic drive belt tensioner, it is essential to bleed the tensioner.

Install the automatic accessory drive belt tensioner onto the engine.

Caution: To prevent damage to the automatic drive belt tensioner, do not apply excessive force after turning the tensioner to the stop.

Using a hex key on the automatic drive belt tensioner, move the automatic tensioner up and down from stop to stop three times to remove air from the tensioner.

Note: As the automatic tensioner is compressed/uncompressed from stop to stop, the piston inside the tensioner moves, forcing air out.

Installing engine mounting support No.3

Caution. If the position of engine support No.3 differs from the original position during reinstallation, this will lead to increased engine noise and vibration. When installing engine mounting support No.3, align the alignment marks applied before removal.

Note:

• If engine mounting support No.3 is replaced, transfer the marks to the new part in the same places where the marks were applied before removing the old mounting support.
• If the nuts securing engine mounting support No.3 are loose, it is necessary to tighten the threaded studs of the front engine cover, since it is they, and not the nuts, that may be loose.

Tighten the threaded studs of the front engine cover to a torque of 40-52 Nm.



Align the alignment marks as shown in the figure and tighten the bolts.



Tighten the nuts shown in the figure, aligning them with the installation marks on the mounting support.

Note: If the alignment marks do not match, align them by moving the engine slightly, then tighten the nuts.

Tighten the bolts and nuts of engine mounting support No.3 in the sequence shown in the figure.


Remove the crossmember from the vehicle.

Install the wiring bracket, coolant hose and connectors.

Install the electronic engine control unit. Connect the connector and install the wiring harness guard.



Tighten the bolts shown in the figure.



Tighten the engine control unit mounting bolts in the sequence shown in the figure to a tightening torque of 9-10 Nm.



Install the ground cable to the ECU bracket.

Installing the oil spray tube

Install the oil spray tube and tighten the mounting bolts in the sequence shown in the figure.

Installing the cylinder head cover

Attention.

• To ensure the tightness of the cylinder head cover, the following must be observed:
• Make sure that the cylinder head cover gasket is inserted into the cover groove and install the cylinder head cover.
• Remove oil, dirt and sealant residue from contact surfaces.
• To prevent premature curing of the silicone sealant, install the cylinder head cover on the engine within 70 minutes after applying the sealant and tighten the mounting bolts immediately.

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

Apply silicone sealant to the areas shown in the figure.



Tighten the two bolts shown in the figure.



Tighten bolts A in the sequence shown in the figure to a torque of 4.5-7.0 Nm.



Tighten bolts B in the sequence shown in the figure to a torque of 4.5-7.0 Nm.

Installation of insulating casing

Position the front edge of the insulator boot so that it is toward the front of the vehicle relative to the exhaust manifold insulator.



Insert the insulating casing until it stops.

Actions after installation of all engine components

Add the required amount of engine oil.

Fill with coolant.

Check the engine cooling system for leaks.

Start the engine and check:

• Presence of engine oil leaks.
• Engine oil level.
• Beating and interference of pulleys and drive belt.
• Engine idle speed.