TIMING CHAIN REMOVAL/INSTALLATION [PYUL]SM3329727
TIMING CHAIN REMOVAL/INSTALLATION [PYUL]

id01101a950600


D-code

• 12201

Remove Capsule Cover

1.Remove in the order indicated in the table.
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Step

Part name
1
Capsule cover
(See Capsule cover removal note)


Capsule cover removal note

1.Turn the fasteners as shown in the figure.
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Remove Cover Assembly (Passenger's Side)

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Cover assembly
(See Cover assembly removal note.)


Cover assembly removal note

Note
• Release the clips according to the lock/unlock mark on the cowl grille cover.

1.Remove the cover assembly as shown in the figure.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure


Disconnect Negative Lead-Acid Battery Terminal


With e-SKYACTIV PHEV

Warning
• Before removing the SRS air bag system-related parts, always disconnect the negative lead-acid battery terminal and wait for 1 min or more to allow the back-up power supply to deplete its stored power.
• Contact with the positive lead-acid battery terminal could cause electrocution due to a short circuit and result in serious injury or death, or damage to vehicle parts. Do not contact the positive lead-acid battery terminal when performing the procedure.
Caution
• If the nut for the current sensor is loosened with the negative lead-acid battery terminal connected to the lead-acid battery, excessive torque will be applied to the negative lead-acid battery terminal and the lead-acid battery terminal will be damaged. When removing the negative lead-acid battery terminal and current sensor, be careful not to damage the lead-acid battery terminal.
• Be careful not to contact the positive lead-acid battery terminal.

1.Verify that the charge cable is not connected to the charging port.

• If the charge cable is connected to the charging port, remove the charge cable.

2.Keep the driver's door open.

3.Keep the hood open.

4.Keep the main power switched ON (READY on) for 3 s or more.

5.Switch the main power OFF and start measuring the time since the main power was switched OFF using a stopwatch.

Caution
• If the cooling fan does not stop after 5 min have elapsed since the main power was switched OFF, wait until it stops.
• If the [Battery cooling] operation notification is displayed on the center display, do not make a selection and leave it as it is.

6.Switch the main power OFF and wait for 5 min.

Warning
• Before servicing after disconnecting the negative lead-acid battery terminal, wait for 1 min or more.
Caution
• If the time since the main power was switched OFF in Step 5 to the disconnection of the negative lead-acid battery terminal exceeds 25 min, perform the procedure from Step 3 again.
Note
• In order to prevent it from falling off, the negative lead-acid battery terminal nut cannot be removed.
• After the negative lead-acid battery is disconnected, there is no restriction on opening/closing the door.

7.Disconnect the negative lead-acid battery terminal within 25 min from switching the main power OFF in Step 5 using the following procedure.

(1)Disconnect the current sensor connector.
(2)Disconnect the negative lead-acid battery terminal.
• When disconnecting a negative lead-acid battery terminal with deformed plastic, expand the gap of the negative lead-acid battery terminal using a flathead screwdriver, and remove the terminal.
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Symbol

Content
5 N·m {51 kgf·cm, 44 in·lbf}


Without e-SKYACTIV PHEV

Warning
• Before removing the SRS air bag system-related parts, always disconnect the negative battery terminal and wait for 1 min or more to allow the back-up power supply to deplete its stored power.
• Contact with the positive battery terminal could system may electrocution due to a short circuit and result in serious injury or death, or damage to vehicle parts. Do not contact the positive battery terminal when performing the procedure.
Caution
• Do not perform servicing for a long period ( 10 min or more) with the engine switch ON (engine stop).

1.Connect the M-MDS to the DLC-2.

2.Turn ON the engine switch (engine stop).

3.Verify the[BATT_SOC] value using the M-MDS data logger function.

4.Record the [BATT_SOC] value.

[BATT_SOC] value is less than 75%
• Inspect the battery.
[BATT_SOC] value is 75% or more
• Go to the next step.

5.Turn OFF the engine switch.

Caution
• If the nut for the current sensor is loosened with the negative battery terminal connected to the battery, excessive torque will be applied to the negative battery terminal and the battery terminal will be damaged. When removing the negative battery terminal and current sensor, be careful not to damage the battery terminal.
• Be careful not to contact the positive battery terminal.

6.Disconnect the current sensor connector.

Note
• The positive battery terminal nut cannot be removed to prevent it from falling off.

7.Disconnect the negative battery terminal.

• When disconnecting the plastic deformed negative battery terminal, expand the gap of the negative battery terminal using a flathead screwdriver for removal.
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Symbol

Content
5 N·m {51 kgf·cm, 44 in·lbf}


Remove Cover Assembly (Driver's Side )

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Cover assembly
(See Cover assembly removal note.)


Cover assembly removal note

Note
• Release the clips according to the lock/unlock mark on the cowl grille cover.

1.Remove the cover assembly as shown in the figure.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure


Remove Driver's Side Windshield Washer Hose (Upper)

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Driver's side windshield washer hose (upper)


Remove Driver's Side Wiper Arm Cover

1.Remove using the procedure shown in the figure.
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Procedure

Part name
1
Windshield washer hose
2
Driver's side wiper arm cover


Remove Driver's Side Windshield Wiper Arm And Blade

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Nut
25.5 N·m {2.6 kgf·m, 18.8 ft·lbf}
2
Driver's side windshield wiper arm and blade
(See Driver's side windshield wiper arm and blade installation note)
—


Driver's side windshield wiper arm and blade installation note

1.Use a wire brush to clean the serrated connecting part.
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Symbol

Content
1
Serration engagement area

• If the serrated connecting part is damaged, replace the windshield wiper motor and link.

2.Align the driver’s side windshield wiper blade end with the hollowed mark in the ceramic coating and install.

• If the hollowed mark in the ceramic coating cannot be located, adjust the driver’s side windshield wiper blade end to the range shown in the figure and install.
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Symbol

Content
8—12 mm {0.32—0.47 in}
1
Ceramic hollow mark
2
Driver's side windshield wiper blade
3
Cowl grille

3.Install the nut.

4.Switch the ignition ON (engine off or on).

5.Operate the windshield wipers at low speed.

6.Turn the windshield wiper switch OFF.

7.Verify that the driver's side windshield wiper is stopped at the park position by the auto-stop function.

• If the driver's side windshield wiper is not installed to the park position, change the driver's side windshield wiper arm and serrated connecting part one groove at a time and adjust it to the park position.


Remove Passenger’s Side Windshield Washer Hose (Upper)

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Passenger’s side windshield washer hose (upper)


Remove Passenger's Side Wiper Arm Cover

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Windshield washer hose
2
Passenger's side wiper arm cover


Remove Passenger’s Side Windshield Wiper Arm And Blade

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Nut
25.5 N·m {2.6 kgf·m, 18.8 ft·lbf}
2
Passenger's side windshield wiper arm and blade
(See Passenger's side windshield wiper arm and blade installation note.)
—


Passenger's side windshield wiper arm and blade installation note

1.Use a wire brush to clean the serrated connecting part.
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Symbol

Content
1
Serration engagement area

• If the serrated connecting part is damaged, replace the windshield wiper motor and link.

2.Align the passenger's side windshield wiper blade end with the hollowed mark in the ceramic coating and install.

• If the hollowed mark in the ceramic coating cannot be located, adjust the passenger's side windshield wiper blade end to the position shown in the figure and install.
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Symbol

Content
13—17 mm {0.52—0.66 in}
1
Ceramic hollow mark
2
Passenger's side windshield wiper blade
3
Front fender molding

3.Install the nuts.

4.Switch the ignition ON (engine off or on).

5.Operate the windshield wipers at low speed.

6.Turn the windshield wiper switch OFF.

7.Verify that the windshield wipers are stopped at the park position by the auto-stop function.

• If the passenger's side windshield wiper is not installed to the park position, change the passenger's side windshield wiper arm and serrated connecting part one groove at a time and adjust it to the park position.


Remove Driver's Side Front Fender Molding

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Front fender molding
(See Front fender molding removal note.)


Front fender molding removal note

1.Remove the front fender molding as shown in the figure.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure


Remove Cowl Grille

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Washer hose
2
Fastener
3
Cowl grille
(See Cowl grille removal note.)
4
Cowl grille weatherstrip
(See Cowl grille weatherstrip removal note.)


Cowl grille removal note

1.Remove the cowl grille as shown in the figure.
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Cowl grille weatherstrip removal note

1.Remove the cowl grille weatherstrip as shown in the figure.
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Remove Passenger's Side Front Fender Molding

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Front fender molding
(See Front fender molding removal note.)


Front fender molding removal note

1.Remove the front fender molding as shown in the figure.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure


Remove Side Cowl Grille (Driver's Side )

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Fastener
2
Side cowl grille


Remove Windshield Wiper Motor And Link

Caution
• Always apply protective tape to the windshield edge. If the windshield wiper motor and link contacts the windshield, it could damage the windshield.
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Symbol

Content
Protective tape attachment positions

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Connector
—
2
Bolt
(See Bolt installation note.)
8.0 N·m {82 kgf·cm, 71 in·lbf}
3
Windshield wiper motor and link
—


Bolt installation note

1.Install the bolts shown in the figure.
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Symbol

Content
Temporarily tighten
8.0 N·m {82 kgf·cm, 71 in·lbf}


Remove Driver Side Strut Tower Bar

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Wiring harness clip
(See Wiring harness clip removal note.)
—
2
Bolt
35 N·m {3.55 kgf·m, 25.8 ft·lbf}
3
Nut
35 N·m {3.55 kgf·m, 25.8 ft·lbf}
4
Strut tower bar
—


Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.
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Remove Passenger Side Strut Tower Bar

1.Remove using the procedure shown in the figure.

• The figure shows the right side (same as left side).
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Step

Part name

Applicable condition
1
Connector
With windshield wiper de-icer
—
2
Wiring harness clip
(See Wiring harness clip removal note.)
—
—
3
Bolt
—
35 N·m {3.55 kgf·m, 25.8 ft·lbf}
4
Nut
—
35 N·m {3.55 kgf·m, 25.8 ft·lbf}
5
Strut tower bar
—
—


Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.
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Remove Engine Compartment Insulator (Upper)

1.Remove in the order indicated in the table.
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Step

Part name
1
Screw
(See Screw installation note)
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Fastener
—
3
Engine compartment insulator (upper)
—


Screw installation note

1.Install the screws as shown in the figure.
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Symbol

Content
Servicing procedure
9.5 N·m {95 kgf·cm, 82 in·lbf}


Remove Air Cleaner Component

1.Remove in the order indicated in the table.
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Step

Part name
1
Ventilation hose
—
2
Connector
—
3
Hose clamp
3 N·m {30 kgf·cm, 26 in·lbf}
4
Bolt
9.5 N·m {95 kgf·cm, 82 in·lbf}
5
Air cleaner component
—


Remove Front Tires(LH)

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Nut
127.5 N·m {13 kgf·m, 94.05 ft·lbf}
2
Wheel and tire
(See Wheel and tire installation note.)
—


Wheel and tire installation note

1.When installing the wheel and tire, tighten the wheel nuts in a criss-cross pattern.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure


Remove Front Tires(RH)

1.Remove using the procedure shown in the figure.

• The figure shows the right side (same as left side).
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Step

Part name
1
Nut
127.5 N·m {13 kgf·m, 94.05 ft·lbf}
2
Wheel and tire
(See Wheel and tire installation note.)
—


Wheel and tire installation note

1.When installing the wheel and tire, tighten the wheel nuts in a criss-cross pattern.

• The figure shows the right side (same as left side).
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Symbol

Content
Servicing procedure


Remove Front Under Cover No.2

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Front under cover No.2
—


Remove Front Under Cover No.1

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
3
Fastener
—
4
Front under cover No.1
—


Remove Front Under Cover No.3

1.Remove using the procedure shown in the figure.
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Front undercover No.3
—


Drain Engine Coolant (Main)

1.Open the coolant reserve tank cap.
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1
Coolant reserve tank cap

2.Drain the engine coolant (main) from the coolant reserve tank.

3.Remove the drain plug (main) and drain the engine coolant (main).
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1
Drain plug (main)

4.Install the drain plug (main).


Remove Passenger Side Edge Rubber

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Edge rubber
(See Edge rubber removal note.)


Edge rubber removal note

1.Partially peel back the cowl grille weatherstrip until the A-pillar trim can be removed.
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2.Remove the edge rubber.


Remove Driver Side Edge Rubber

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Edge rubber
(See Edge rubber removal note.)


Edge rubber removal note

1.Partially peel back the cowl grille weatherstrip until the A-pillar trim can be removed.
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2.Remove the edge rubber.


Remove Passenger Side Front Over Fender Lower

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Front over fender lower
(See Front over fender lower removal note.)
(See Front over fender lower installation note.)


Front over fender lower removal note

1.Press the front over fender lower in the direction of the arrow (1) shown in the figure to create a gap of approx. 3 mm {1 in} between the front over fender lower and the front fender.

• The figure shows the left side (same as right side).
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Symbol

Content
Approx. 3 mm {0.1 in}

2.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).
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Symbol

Content
Protective tape attachment positions

3.Insert a remover tool into the position shown in the figure, move it in the direction of the arrow, and then detach the clip from the body.

• The figure shows the left side (same as right side).
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Symbol

Content
50 mm {2.0 in}
25 mm {0.98 in}

4.Detach the clips from the body using a remover tool.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure

5.Remove the front over fender lower.


Front over fender lower installation note

Warning
• If the front over fender lower is installed with the clips damaged, the front over fender lower may fall off while the vehicle is being driven, leading to a serious accident. If the clips are damaged, replace them with new one.


Remove Passenger Side Front Over Fender Upper

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Front over fender upper
(See Front over fender upper removal note.)
(See Front over fender upper installation note.)


Front over fender upper removal note

1.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).
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Symbol

Content
Protective tape attachment positions

2.Pull the front over fender upper in the direction of the arrow shown in the figure and detach the clips from the front bumper.

• The figure shows the left side (same as right side).
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3.Using a tape-wrapped fastener remover, move it in the direction of the arrow shown in the figure and detach the clips from the body.

• The figure shows the left side (same as right side).
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Symbol

Content
300 mm {1.18 in} or more
Servicing procedure

4.Remove the front over fender upper.


Front over fender upper installation note

Warning
• If the front over fender upper is installed with the clips damaged, the front over fender upper may fall off while the vehicle is being driven, leading to a serious accident. If the clips are damaged, replace them with new one.


Remove Driver Side Front Mudguard

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Fastener
—
4
Fastener
—
5
Fastener
—
6
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
7
Fastener
—
8
Front mudguard
—


Remove Driver Side Front Over Fender Lower

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Front over fender lower
(See Front over fender lower removal note.)
(See Front over fender lower installation note.)


Front over fender lower removal note

1.Press the front over fender lower in the direction of the arrow (1) shown in the figure to create a gap of approx. 3 mm {1 in} between the front over fender lower and the front fender.

• The figure shows the left side (same as right side).
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Symbol

Content
Approx. 3 mm {0.1 in}

2.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).
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Symbol

Content
Protective tape attachment positions

3.Insert a remover tool into the position shown in the figure, move it in the direction of the arrow, and then detach the clip from the body.

• The figure shows the left side (same as right side).
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Symbol

Content
50 mm {2.0 in}
25 mm {0.98 in}

4.Detach the clips from the body using a remover tool.

• The figure shows the left side (same as right side).
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Symbol

Content
Servicing procedure

5.Remove the front over fender lower.


Front over fender lower installation note

Warning
• If the front over fender lower is installed with the clips damaged, the front over fender lower may fall off while the vehicle is being driven, leading to a serious accident. If the clips are damaged, replace them with new one.


Remove Driver Side Front Over Fender Upper

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Front over fender upper
(See Front over fender upper removal note.)
(See Front over fender upper installation note.)


Front over fender upper removal note

1.Apply protective tape to the location shown in the figure to prevent scratches or damage.

• The figure shows the left side (same as right side).
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Symbol

Content
Protective tape attachment positions

2.Pull the front over fender upper in the direction of the arrow shown in the figure and detach the clips from the front bumper.

• The figure shows the left side (same as right side).
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3.Using a tape-wrapped fastener remover, move it in the direction of the arrow shown in the figure and detach the clips from the body.

• The figure shows the left side (same as right side).
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Symbol

Content
300 mm {1.18 in} or more
Servicing procedure

4.Remove the front over fender upper.


Front over fender upper installation note

Warning
• If the front over fender upper is installed with the clips damaged, the front over fender upper may fall off while the vehicle is being driven, leading to a serious accident. If the clips are damaged, replace them with new one.


Remove Passenger Side Front Mudguard

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Fastener
—
4
Fastener
—
5
Fastener
—
6
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
7
Fastener
—
8
Front mudguard
—


Remove Passenger Side Front Deflector

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
—
2
Fastener
(See Fastener removal note.)
—
3
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
4
Front deflector
—


Fastener removal note

1.Partially peel back the front over fender upper until the fasteners can be removed as shown in the figure.

• The figure shows the left side (same as right side).
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2.Remove the fasteners.


Remove Driver Side Front Deflector

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
—
2
Fastener
(See Fastener removal note.)
—
3
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
4
Front deflector
—


Fastener removal note

1.Partially peel back the front over fender upper until the fasteners can be removed as shown in the figure.

• The figure shows the left side (same as right side).
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2.Remove the fasteners.


Remove Passenger Side Front Splash Shield No.1

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
—
2
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
3
Front splash shield No.1
—


Remove Passenger Side Front Splash Shield No.2

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
2
Front splash shield No.2


Front splash shield No.2 removal note

1.Move the front splash shield No.2 in the direction of the arrow shown in the figure, remove the front splash shield No.2 tab from the engine mount.
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Remove Driver Side Front Splash Shield No.1

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
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Step

Part name
1
Fastener
—
2
Screw
2 N·m {20 kgf·cm, 17 in·lbf}
3
Front splash shield No.1
—


Remove Driver Side Front Splash Shield No.2

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
azzdjw00000575

Step

Part name
1
Fasteners
2
Front splash shield No.2


Front splash shield No.2 removal note

1.Move the front splash shield No.2 in the direction of the arrow shown in the figure, remove the front splash shield No.2 tab from the engine mount.
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Remove Front Bumper

1.Remove using the procedure shown in the figure.
azzdjw00000884

Step

Part name

Applicable condition
1
Bolt
—
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Fastener
—
—
3
Latch Cover
—
—
4
Fastener
—
—
5
Bolt
—
8.5 N·m {85 kgf·cm, 74 in·lbf}
6
Bolt
—
8.5 N·m {85 kgf·cm, 74 in·lbf}
7
Fastener
—
—
8
Front bumper
(See Front bumper removal note.)
—
—
9
Connector
With 360° view monitor
—
10
Connector
—
—
11
Wiring harness clip
(See Wiring harness clip removal note.)
—
—
12
Headlight washer hose
With headlight washer
—


Front bumper removal note

Caution
• If the front bumper and the front bumper sliders are forcibly detached, the parts may be damaged. Be careful when detaching the front bumper from the front bumper sliders.
• Removing the front bumper without supporting it could cause the front bumper to fall and cause serious injury. Always perform the procedure with at least one other person to prevent the front bumper from falling.

1.Remove the front bumper as shown in the figure.

• The figure shows the left side (same as right side).
azzdjw00000885

Symbol

Content
Protective tape attachment positions
Servicing procedure


Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.
azzdjw00000887


Remove Center Seal Plate

1.Remove using the procedure shown in the figure.
azzdjw00003455

Step

Part name
1
Fasteners
2
Fasteners
3
Center seal plate


Remove Bracket

Caution
• Perform the procedure with the condenser secured to the body with a string.
azzdjw00001681

1.Remove using the procedure shown in the figure.
azzdjw00003780

Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fasteners
—
3
Bracket
(See Bracket installation note.)
—


Bracket installation note

1.After installing the front bumper, refer to [HOOD ADJUSTMENT] and measure the space between the hood and the front bumper.

2.If the measured value is not within the standard, move the front bumper bracket and adjust the installation position.


Remove Intake Air Guide (Upper)

1.Remove using the procedure shown in the figure.
azzdjw00003781

Step

Part name
1
Intake air guide (upper)
(See Intake air guide (upper) removal note.)


Intake air guide (upper) removal note

1.Remove the intake air guide (upper) as shown in the figure.
azzdjw00001683

2.Verify that the intake air guide (upper) is inserted into the seal plate and engaged.

• The figure shows the left side (same as right side).
azzdjw00007519


Remove Passenger's Side Seal Plate

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
azzdjw00003783

Step

Part name
1
Fasteners
2
Seal plate
(See Passenger's Side seal plate installation note.)


Passenger's Side seal plate installation note

1.Verify that the passenger's side seal plate is inserted into the intake air guide (lower) groove and engaged.

• The figure shows the left side (same as right side).
azzdjw00007520


Remove Driver's Side Seal Plate

1.Remove using the procedure shown in the figure.

• The figure shows the left side (same as right side).
azzdjw00003782

Step

Part name
1
Fasteners
2
Seal plate
(See Driver's side seal plate installation note.)


Driver's side seal plate installation note

1.Verify that the driver's side seal plate is inserted into the intake air guide (lower) groove and engaged.

• The figure shows the left side (same as right side).
azzdjw00007520


Remove Member Bracket (LH)

1.Remove using the procedure shown in the figure.
azzdjw00003111

Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Front mudguard (LH)
(See Partially peeling back front mudguard (LH) note)
—
4
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
5
Bolt
82 N·m {8.35 kgf·m, 60.35 ft·lbf}
6
Member bracket
—


Partially peeling back front mudguard (LH) note

1.Remove the bolt and fasteners and partially peel back the front mudguard.


Remove Member Bracket (RH)

1.Remove using the procedure shown in the figure.
azzdjw00003112

Step

Part name
1
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
2
Fastener
—
3
Front mudguard (RH)
(See Partially peeling back front mudguard (RH) note.)
—
4
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
5
Bolt
82 N·m {8.35 kgf·m, 60.35 ft·lbf}
6
Member bracket (RH)
—


Partially peeling back front mudguard (RH) note

1.Remove the bolt and fasteners and partially peel back the front mudguard.


Remove Radiator Mount (LH)

1.Remove in the order indicated in the table.
azzdjw00005754

Step

Part name
1
Bolt
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Radiator mount (LH)
—


Remove Radiator Mount (RH)

1.Remove in the order indicated in the table.
azzdjw00006812

Step

Part name
1
Bolt
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Radiator mount (RH)
—


Lower Engine Component 50 mm {2.0 in}

1.Remove in the order indicated in the table.
azzezw00000512

Step

Part name
1
Clip
—
2
Bolt
9.5 N·m {95 kgf·cm, 82 in·lbf}
3
Bolt
11 N·m {110 kgf·cm, 95 in·lbf}
4
Bolt
9.5 N·m {95 kgf·cm, 82 in·lbf}
5
Clip
—
6
Clip
—
7
Clip
—
8
Clip
—
9
Connector
—
10
Clip
—
11
Clip
—
12
Clip
—
13
Clip
—
14
Clip
—

azzdjw00007404

Step

Part name
1
Bolt
(See Lowering engine component 50 mm {2.0 in} note)
—
210.5 N·m {21.45 kgf·m, 155.1 ft·lbf}
2
Bolt
(See Lowering engine component 50 mm {2.0 in} note)
—
82.5 N·m {8.4 kgf·m, 60.85 ft·lbf}
3
Engine component
(See Lowering engine component 50 mm {2.0 in} note)
49 JP01 1A0
—


Lowering engine component 50 mm {2.0 in} note

Warning
• Due to a difference in height between the X mark and the front crossmember, verify that they make contact at the same time.

1.Place the X mark on the front crossmember in front of the engine lifter.
azzdjw00007406

1
X mark

2.Place impact-absorbing material in the area where the front crossmember makes contact.

Warning
• At this time, the platform of the engine lifter must be higher than the handle. If it is at a lower position, it may contact the vehicle and cause damage.

3.Raise the engine lifter to a position 20 mm {0.79 in} lower than its highest position.

Warning
• Lower while checking the area around the engine, such as whether an excessive load is applied lengthwise.

4.Slowly lower the lift until the engine component rests on the engine lifter.

5.When removing the front crossmember bolts, raise the engine lifter to reduce the load applied to the bolts.

6.Remove the front crossmember bolts.

Caution
• If only the bolts in one area are removed, a load may be applied to the remaining bolts. Therefore, remove the bolts evenly.
azzdjw00007407

7.Temporarily tighten the SSTs shown in the figure.

azzezw00000513

Symbol

Content
Servicing procedure
Temporarily tighten
49 JP01 1A0

8.Lower the engine lifter and slightly lower the front crossmember.

9.Set the SSTs in the space created by slightly lowering the front crossmember.

azzdjw00007409

Symbol

Content
49 JP01 1A0

10.Tighten the SSTs in the order shown in the figure.

azzdjw00007410

Symbol

Content
Servicing procedure
49 JP01 1A0
82.5 N·m {8.4 kgf·m, 60.85 ft·lbf}
210.5 N·m {21.45 kgf·m, 155.1 ft·lbf}

11.Lower the engine lifter.


Remove Oil Pan Drain Plug

1.Remove in the order indicated in the table.
azzdjw00005577

Step

Part name
1
Oil pan drain plug
—
2
Gasket
Replacement part


Engine oil sampling [PYUL]

1.Drain the engine oil into a container.

2.Wait until the engine oil starts to drip.


Install Oil Pan Drain Plug

1.Install in the order indicated in the table.
azzdjw00006745

Step

Part name
1
Oil pan drain plug
—
35.5 N·m {3.6 kgf·m, 26.05 ft·lbf}
2
Gasket
Replacement part
—


Remove Front Brake Disc

1.Remove using the procedure shown in the figure.
azzezw00000153

Step

Part name
1
Bolt
164 N·m {17 kgf·m, 121 ft·lbf}
2
Front brake caliper component
(See Front brake caliper component removal note)
(See Front brake caliper component installation note)
—
3
Disc plate
—


Front brake caliper component removal note

1.Remove the front brake caliper component and suspend it in a place out of the way using a cable.
am3zzw00022399


Front brake caliper component installation note

1.Press in the piston using a commercially available disc brake expander tool.
azzezw00000154

2.Install the front brake caliper component.


Remove Front Drive Shaft (LH) (AWD)

Caution
• If the front ABS wheel-speed sensor wiring harness is pulled by mistake when performing this procedure, it could cause open circuit. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

1.Remove using the procedure shown in the figure.
azzdjw00003184

Step

Part name
1
Bolt
—
—
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Front ABS wheel-speed sensor
(See Front ABS wheel-speed sensor disconnection note.)
—
—
—
3
Locknut
(See Locknut removal note.)
(See Locknut installation note.)
Replacement part
—
Tighten to 125 N·m {12.75 kgf·m, 92.2 ft·lbf}
Loosen to 180°.
Tighten to 255 N·m {26 kgf·m, 187.95 ft·lbf}
4
Nut
—
—
42.5 N·m {4.3 kgf·m, 31.15 ft·lbf}
5
Bolt
—
—
—
6
Front upper arm ball joint
(See Front upper arm ball joint connection note.)
—
—
—
7
Tie-rod end
(See Tie-rod end disconnection note.)
—
49 T028 3A0
—
8
Nut
—
—
74.5 N·m {7.6 kgf·m, 55 ft·lbf}
9
Nut
—
—
138 N·m {14.05 kgf·m, 101.75 ft·lbf}
10
Steering knuckle, hub component, dust cover
(See Steering knuckle, hub component, and dust cover installation note.)
—
—
—
11
Front drive shaft
(See Front drive shaft removal note.)
(See Front drive shaft installation note.)
—
49 B025 017
49 B025 010
—
12
Front drive shaft clip
(See Front drive shaft clip installation note.)
Replacement part
—
—


Front ABS wheel-speed sensor disconnection note

1.Disconnect the front ABS wheel-speed sensor wiring harness and set it aside so that it does not interfere with the servicing.


Locknut removal note

Caution
• If an electric tool or a pneumatic tool is used when removing the locknut, the locknut may seize. Do not use electric tools or pneumatic tools and remove the locknut manually.
• The wheel hub may be damaged if a ground load is applied to the axle when the locknut is removed. Remove the locknut without applying a ground load to the axle.

1.Remove the locknut with the brake pedal depressed.

2.Temporarily tighten a spare nut to the front drive shaft

3.Tap the nut with a copper hammer and separate the front drive shaft from the axle.
azzdjw00001460


Tie-rod end disconnection note

1.Disconnect the tie-rod end joint using the following procedure.

(1)Loosen the nut.
(2) SSTDetach the tie-rod end from the steering knuckle using the SST.
azzdjw00001461

Symbol
Content
49 T028 3A0


Front drive shaft removal note

1.Install SST(49 B025 017) to SST(49 B025 010).

2.Disengage the front differential from the front drive shaft using the SST.

azzdjw00001462

Symbol

Content
49 B025 010
49 B025 017


Front drive shaft clip installation note

1.Install a new clip to the clip groove at the end of the front drive shaft with the clip opening facing upward.
azzdjw00001464

Symbol

Content
Front drive shaft clip
Less than 29.5 mm {1.16 in}

2.Verify that the outer diameter of the clip is within the standard.

• If it exceeds the standard, repeat installation using a new clip.


Front drive shaft installation note

Caution
• The oil seal could be damaged at the end area of the front drive shaft. When installing the front drive shaft to the transaxle, be careful not to damage the oil seal.

1.Apply front differential oil to the oil seal lip.

2.Install the front drive shaft to the front differential.

3.Verify that the front drive shaft is securely held by the clip.


Steering knuckle, hub component, and dust cover installation note

1.Apply grease (D4Y0 33247) to the wheel bearing inner race and front drive shaft contact surfaces.
azzdjw00003185

Symbol

Content
D4Y0 33247 Application area

2.Install the steering knuckle, hub component, and dust cover as a single unit.


Front upper arm ball joint connection note

Caution
• If any problem such as deformation is found with the dust cover plate, replace the front upper arm with a new one. Otherwise, an operation malfunction or rust may occur inside the ball joint due to foreign matter or water infiltration or another cause, leading to damage of the ball joint.
azzdjw00001466

1.Insert the upper arm ball joint into the steering knuckle.

2.Verify that the upper arm ball joint is fully inserted.

3.Insert the bolt from the rear of the vehicle and install the upper arm ball joint.


Locknut installation note

Caution
• If an electric tool or a pneumatic tool is used when installing a locknut, the locknut may seize and the tightening force of the wheel hub may be reduced, causing rattling and abnormal noise. Do not use electric tools or pneumatic tools and install the locknut manually.
• If a ground load is applied to the axle when the locknut is removed, the wheel hub may be damaged. Install the locknut without applying a ground load to the axle.

1.If dust or grease is on the drive shaft thread area, wipe it off with a cloth.

2.Working with two people, one should depress and hold the brake pedal down.

3.While the other technician is depressing the brake pedal, tighten the locknut using the following procedure.

(1) Tighten to 125 N·m {12.75 kgf·m, 92.2 ft·lbf}
(2) Loosen to 180°.
(3) Tighten to 255 N·m {26 kgf·m, 187.95 ft·lbf}


Remove Front Drive Shaft (RH) (AWD)

Caution
• If the front ABS wheel-speed sensor wiring harness is pulled by mistake when performing this procedure, it could cause open circuit. Before servicing, disconnect the front ABS wheel-speed sensor and set it aside so that the wiring harness will not be pulled by mistake.

1.Remove using the procedure shown in the figure.
azzdjw00003188

Step

Part name
1
Bolt
—
—
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Front ABS wheel-speed sensor
(See Front ABS wheel-speed sensor disconnection note.)
—
—
—
3
Locknut
(See Locknut removal note.)
(See Locknut installation note.)
Replacement part
—
Tighten to 125 N·m {12.75 kgf·m, 92.2 ft·lbf}
Loosen to 180°.
Tighten to 255 N·m {26 kgf·m, 187.95 ft·lbf}
4
Nut
—
—
42.5 N·m {4.3 kgf·m, 31.15 ft·lbf}
5
Bolt
—
—
—
6
Front upper arm ball joint
(See Front upper arm ball joint connection note.)
—
—
—
7
Tie-rod end
(See Tie-rod end disconnection note.)
—
49 T028 3A0
—
8
Nut
—
—
74.5 N·m {7.6 kgf·m, 55 ft·lbf}
9
Nut
—
—
138 N·m {14.05 kgf·m, 101.75 ft·lbf}
10
Steering knuckle, hub component, dust cover
(See Steering knuckle, hub component and dust cover installation note.)
—
—
—
11
Nut
—
—
25 N·m {2.55 kgf·m, 18.45 ft·lbf}
12
Front drive shaft (passenger side)
(See Front drive shaft installation note.)
—
—
—


Front ABS wheel-speed sensor disconnection note

1.Disconnect the front ABS wheel-speed sensor wiring harness and set it aside so that it does not interfere with the servicing.


Locknut removal note

Caution
• If an electric tool or a pneumatic tool is used when removing the locknut, the locknut may seize. Do not use electric tools or pneumatic tools and remove the locknut manually.
• The wheel hub may be damaged if a ground load is applied to the axle when the locknut is removed. Remove the locknut without applying a ground load to the axle.

1.Remove the locknut with the brake pedal depressed.

2.Temporarily tighten a spare nut to the front drive shaft

3.Tap the nut with a copper hammer and separate the front drive shaft from the axle.
azzdjw00001468


Tie-rod end disconnection note

1.Disconnect the tie-rod end joint using the following procedure.

(1)Loosen the nut.
(2) SSTDetach the tie-rod end from the steering knuckle using the SST.
azzdjw00001469

Symbol
Content
49 T028 3A0


Front drive shaft installation note

Caution
• The oil seal could be damaged at the end area of the front drive shaft. When installing the front drive shaft to the front differential, be careful not to damage the oil seal.

1.Apply front differential oil to the oil seal lip.

2.Insert the front drive shaft into the engine.

3.Temporarily tighten the nuts shown in the figure and then completely tighten them.
azzdjw00001470


Steering knuckle, hub component and dust cover installation note

1.Apply grease (D4Y0 33247) to the wheel bearing inner race and front drive shaft contact surfaces.
azzdjw00003189

Symbol

Content
D4Y0 33247 Application area

2.Install the steering knuckle, hub component, and dust cover as a single unit.


Front upper arm ball joint connection note

Caution
• If any problem such as deformation is found with the dust cover plate, replace the front upper arm with a new one. Otherwise, an operation malfunction or rust may occur inside the ball joint due to foreign matter or water infiltration or another cause, leading to damage of the ball joint.
azzdjw00001472

1.Insert the upper arm ball joint into the steering knuckle.

2.Verify that the upper arm ball joint is fully inserted.

3.Insert the bolt from the rear of the vehicle and install the upper arm ball joint.


Locknut installation note

Caution
• If an electric tool or a pneumatic tool is used when installing a locknut, the locknut may seize and the tightening force of the wheel hub may be reduced, causing rattling and abnormal noise. Do not use electric tools or pneumatic tools and install the locknut manually.
• If a ground load is applied to the axle when the locknut is removed, the wheel hub may be damaged. Install the locknut without applying a ground load to the axle.

1.If dust or grease is on the drive shaft thread area, wipe it off with a cloth.

2.Working with two people, one should depress and hold the brake pedal down.

3.While the other technician is depressing the brake pedal, tighten the locknut using the following procedure.

(1) Tighten to 125 N·m {12.75 kgf·m, 92.2 ft·lbf}
(2) Loosen to 180°.
(3) Tighten to 255 N·m {26 kgf·m, 187.95 ft·lbf}


Remove The Front Crossmember Component

Caution
• There is risk of damaging the part. Perform the procedure with the radiator component secured to the body with rope.
azzdjw00001681
Note
• After installation, check wheel alignment and make adjustments if necessary.

1.Remove using the procedure shown in the figure.

Step 1
azzdjw00003968

Step

Part name

Applicable condition
1
Nut
—
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Water pipe and hose
—
—
3
Nut
—
9.5 N·m {95 kgf·cm, 82 in·lbf}
4
Electric water pump No.1
—
—
5
Bolt
T3
22 N·m {2.25 kgf·m, 16.25 ft·lbf}
6
Water pipe and hose
T3
—
7
Wiring harness clip
—
—
8
Connector
—
—
9
Wiring harness clip
—
—
10
Wiring harness clip
(See Wiring harness clip removal note.)
Vehicles with active air shutter
—

Step 2
ac6wzw00000826

Step

Part name
1
Nut
—
138 N·m {14.05 kgf·m, 101.75 ft·lbf}
2
Tie-rod end
(See Tie-rod end disconnection note.)
—
—
3
Nut
—
74.5 N·m {7.6 kgf·m, 55 ft·lbf}
4
Bolt
—
—
5
Nut
—
158 N·m {16.15 kgf·m, 116.7 ft·lbf}
6
Damper fork
(See Damper fork installation note.)
—
—
7
Joint bolt
(See Joint bolt installation note.)
Replacement part
29 N·m {2.95 kgf·m, 21.4 ft·lbf}
8
Intermediate shaft
—
—
9
Bolt
(See Bolt removal note.)
(See Bolt installation note.)
—
50 N·m {5.1 kgf·m, 36.9 ft·lbf}
10
Front crossmember component
(See Front crossmember component removal note.)
—
—


Wiring harness clip removal note

1.Remove the wiring harness clips as shown in the figure.
azzdjw00004142


Tie-rod end disconnection note

1.Disconnect the tie-rod end joint using the following procedure.

(1)Loosen the nut.
(2) SSTUsing the SST, disengage the tie-rod end from the steering knuckle.
• Figure also shows the left side (same for the right side).
azzdjw00001461

Symbol
Content
49 T028 3A0


Bolt removal note

1.Make alignment marks at the locations shown in the figure.

• Figure also shows the left side (same for the right side).
azzdjw00003970

2.Set and hold a jack to the engine oil pan
ac6jjw00000936

3.Remove the bolts.


Front crossmember component removal note

1.Remove the SSTs at the positions shown in the figure and remove the front crossmember component.
ac6jjw00000937


Bolt installation note

1.Align with the alignment mark and install.

• Figure also shows the left side (same for the right side).
azzdjw00003970

2.After temporarily tightening bolt, completely tighten them.


Joint bolt installation note

1.Align with the U-shape groove of the steering gear (pinion) and install a new joint bolt.
azzdjw00000764

Symbol
Content
Joint bolt


Damper fork installation note

1.Insert the bolt shown in the figure from the front of the vehicle and temporarily tighten the nut.

• Figure also shows the left side (same for the right side).
azzdjw00000492

2.Lower the vehicle to the ground and tighten the nut to the specified torque.


Remove Front Propeller Shaft (AWD)

1.Remove using the procedure shown in the figure.
azzdjw00000741

Step

Part name
1
Bolt
91 N·m {9.25 kgf·m, 67.05 ft·lbf}
2
Transverse member
—
3
Bolt
8.5 N·m {84 kgf·cm, 73 in·lbf}
4
Bolt
26 N·m {2.65 kgf·m, 19.2 ft·lbf}
5
Front propeller shaft
—


Remove Front Differential (AWD)

1.Remove using the procedure shown in the figure.
azzdjw00000740

Procedure

Part name

Applicable condition
1
Bolt
Continuous
26 N·m {2.65 kgf·m, 19.2 ft·lbf}
2
Bolt
Continuous
76.5 N·m {7.8 kgf·m, 56.4 ft·lbf}
3
Front differential
Continuous
—


Remove Engine Mount (LH)

1.Remove in the order indicated in the table.
azzdjw00006634

Step

Part name
1
Nut
9.5 N·m {95 kgf·cm, 82 in·lbf}
2
Nut
(See Nut removal note)
(See Engine mount (LH) installation note)
98 N·m {10 kgf·m, 72.45 ft·lbf}
3
Nut
(See Nut removal note)
(See Nut installation note)
98 N·m {10 kgf·m, 72.45 ft·lbf}
4
Bolt
(See Bolt removal note)
(See Engine mount (LH) installation note)
50 N·m {5.1 kgf·m, 36.9 ft·lbf}
5
Engine mount (LH)
(See Engine mount (LH) removal note)
(See Engine mount (LH) installation note)
—


Nut removal note

1.Place alignment marks at the positions shown in the figure so that they can be assembled to the same positions as before removal.
azzdjw00006636

Symbol

Content
1
Alignment mark

2.Remove the nuts.


Nut removal note

1.Place alignment marks at the positions shown in the figure so that they can be assembled to the same positions as before removal.
azzdjw00006637

Symbol

Content
1
Alignment mark

2.Remove the nuts.


Bolt removal note

Caution
• When supporting the engine, perform the following procedure to prevent oil pan deformation.
― When using an engine lifter: Place an appropriate rubber strip (approx. 20 mm {0.79 in} thick) between the engine lifter and the oil pan to support the oil pan.
― When using a garage jack: Place an appropriate rubber strip (approx. 20 mm {0.79 in} thick) on a wooden board that is large enough to cover the oil pan to support the oil pan.

1.Support the engine (oil pan) using a commercially available engine lifter or garage jack.
azzdjw00006638

Symbol

Content
1
Oil pan
2
Rubber
3
Engine lifter
Approx. 20 mm {0.79 in}

2.Remove the bolt.


Engine mount (LH) removal note

1.Tighten the engine mount (LH) stud bolt.

• Tighten the stud bolt because it may have loosened.
azzezw00000901

Symbol

Content
34 N·m {3.45 kgf·m, 25.1 ft·lbf}

2.Remove the SST using the procedure shown in the figure.
azzdjw00006640

Symbol

Content
49 JP01 1A0

3.Remove the engine mount (LH).


Engine mount (LH) installation note

1.Align the alignment marks on the body side with the engine mount (LH) and install the bolts and nuts as shown in the figure.

• If the alignment marks have deviated, align them by slightly moving the engine.
azzdjw00006642

Symbol

Content
Servicing procedure
Temporarily tighten
50 N·m {5.1 kgf·m, 36.9 ft·lbf}
98 N·m {10 kgf·m, 72.45 ft·lbf}

2.Install the SST using the procedure shown in the figure.
azzdjw00006646

Symbol

Content
49 JP01 1A0
83 N·m {8.45 kgf·m, 61.05 ft·lbf}


Nut installation note

1.Tighten the engine mount (LH) stud bolt.

• Tighten the stud bolt because it may have loosened.
azzezw00000901

Symbol

Content
34 N·m {3.45 kgf·m, 25.1 ft·lbf}

2.Install the nuts using the procedure shown in the figure.

• If the alignment marks have deviated, align them by slightly moving the engine.
azzdjw00006647

Symbol

Content
Servicing procedure
Temporarily tighten
98 N·m {10 kgf·m, 72.45 ft·lbf}


Remove oil pan

1.Remove in the order indicated in the table.
azzdjw00006773

Step

Part name
1
Bolt
(See Bolt removal note)
(See Bolt Installation Note)
—
23 N·m {2.35 kgf·m, 16.95 ft·lbf}
2
Oil pan
(See Oil Pan Installation Note)
TB1217D
—


Bolt removal note

1.Install the engine mount

2.Install the nuts in the order shown in the figure.

• If the alignment marks have deviated, align them by slightly moving the engine, and temporarily tighten the nuts.
azzdjw00006776

Symbol

Content
Servicing procedure
Temporarily tighten
98 N·m {10 kgf·m, 72.45 ft·lbf}

3.install the SST in the order shown in the figure.
azzdjw00006779

Symbol

Content
49 JP01 1A0
83 N·m {8.45 kgf·m, 61.05 ft·lbf}

4.Remove the engine lifter or the garage jack.

5.Remove the bolts.


Oil Pan Installation Note

1.Completely remove any oil, dirt, and silicone sealant adhering to the cylinder block and oil pan.

Caution
• If a bolt with a fixed liquid gasket is used, cracks may occur in the cylinder block, etc.
azzdjw00006781

Symbol

Content
1
Fixed liquid gasket
2
Breakage

2.When re-using the oil pan mounting bolt, cleanly remove the liquid gasket attached to the bolt.

Caution
• The liquid gasket should be applied so that there are no gaps all around.
• To prevent silicone sealant from hardening, seal the rear pan to the cylinder BLOCK firmly within 10 min after applying silicone sealant. After sealing, complete the installation bolt tightening immediately.

3.Apply silicone sealant (TB1217D) to the areas shown in the figure.
azzdjw00006782

Symbol

Content
3.0—7.0 mm {0.12—0.27 in}

4.Install the oil pan.


Bolt Installation Note

Caution
• Remove any silicone sealant which oozes out into an oil pan installation bolt hole. If silicone sealant penetrates an oil pan installation bolt hole, the cylinder block could become damaged.
azzdjw00006784

Symbol

Content
1
Silicone sealant
2
Breakage

1.Install the bolts in the order shown in the figure.
azzdjw00006785

Symbol

Content
Servicing procedure
23 N·m {2.35 kgf·m, 16.95 ft·lbf}


Remove Water Pump Drive Belt

1.Remove in the order indicated in the table.
azzdjw00004394

Step

Part name
1
Water Pump Drive Belt
(See Water pump drive belt removal note)
(See Water pump drive belt installation note)


Water pump drive belt removal note

1.Apply a cloth to the water pump drive belt as shown in the figure.
azzdjw00004395

1
Rag
2
Water Pump Drive Belt

2.Pull the cloth in the direction of the arrow and rotate the crankshaft pulley clockwise.
azzdjw00004396

1
Rag
2
Crankshaft pulley

3.Remove the water pump drive belt.


Water pump drive belt installation note

1.Set one side of the water pump drive belt in the groove of the crankshaft pulley.

2.Set the other side of the water pump drive belt in the step of the water pump pulley.
azzdjw00004397

1
Water Pump Drive Belt
2
Water pump pulley

3.Pushing up the belt so that it is fitted in from the step of the water pump pulley to the groove of the pulley, rotate the crankshaft pulley clockwise.
azzdjw00004398

1
Water Pump Drive Belt
2
Water pump pulley

4.After the belt is installed, rotate the crankshaft pulley clockwise approx. 180° and verify that the water pump drive belt is installed correctly.

• If the belt ribs and the pulley grooves are not engaged correctly, remove the belt and reinstall it.


Remove Crankshaft Pulley

1.Remove using the procedure shown in the figure.
azzdjw00006268

Procedure

Part name
1
Crankshaft pulley lock bolt
(See Crankshaft Pulley Lock Bolt Removal Note)
(See Crankshaft pulley lock bolt installation note)
49 B011 105
205-072 (component part or 49 UN20 5072)
110 N·m {11.2 kgf·m, 81.15 ft·lbf}
+55—65°
2
Crankshaft pulley
—
—


Crankshaft Pulley Lock Bolt Removal Note

Caution
• To prevent damage to the crankshaft pulley, protect the crankshaft pulley with a cloth so that the bar part (49 UN20 5072) of the SST does not contact the crankshaft pulley.
• To prevent damage to the engine front cover, be careful not to let the hook part (49 B011 105) of the SST get caught between the crankshaft pulley and engine front cover.

1.Install the SST to the crankshaft pulley to lock the crankshaft against rotation.
azzdjw00006271

Symbol

Content
49 B011 105
205-072 (component part for 49 UN20 5072)

2.Remove the crankshaft pulley lock bolt.


Crankshaft pulley lock bolt installation note

Caution
• To prevent damage to the crankshaft pulley, protect the crankshaft pulley with a cloth so that the bar part (49 UN20 5072) of the SST does not contact the crankshaft pulley.
• To prevent damage to the engine front cover, be careful not to let the hook part (49 B011 105) of the SST get caught between the crankshaft pulley and engine front cover.

1.Install the SST to the crankshaft pulley to lock the crankshaft against rotation.
azzdjw00006273

Symbol

Content
49 B011 105
205-072 (component part for 49 UN20 5072)

2.Tighten the crankshaft pulley lock bolt in two steps.


Remove Ignition Coils

1.Remove in the order indicated in the table.
azzdjw00004371

Step

Part name
1
Connector
—
2
Bolt
9.5 N·m {97 kgf·cm, 84 in·lbf}
3
Ignition coil
—


Remove Dipstick

1.Remove using the procedure shown in the figure.
azzdjw00004789

Procedure

Part name
1
Dipstick


Remove Cylinder Head Cover

1.Remove in the order indicated in the table.
azzdjw00005823

Step

Part name
1
Connector
—
—
2
Wiring harness clip
—
—
3
Bolt
—
9.5 N·m {97 kgf·cm, 84 in·lbf}
4
Ventilation hose
—
—
5
Bolt
—
6.5 N·m {66 kgf·cm, 58 in·lbf}
6
Cylinder head cover
(See Cylinder Head Cover Installation Note)
—
—
7
Gasket
Replacement part
—


Cylinder Head Cover Installation Note

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

2.Apply silicone sealant to the positions shown in the figure.
azzdjw00005825

Symbol

Content
1
Engine front side
2
Cylinder head
3
Engine front cover
4
Engine rear side
5
Exhaust side rear camshaft cap
TB1217D
1 mm {0.04 in}
2 mm {0.08 in}
3 mm {0.1 in}
6 mm {0.2 in}
8 mm {0.3 in}
13 mm {0.51 in}

3.Install the cylinder head cover.

4.Install the bolts shown in the figure.
azzdjw00005833

Symbol

Content
Servicing procedure
Temporarily tighten
6.5 N·m {66 kgf·cm, 58 in·lbf}

5.Measure the tightening torque again and verify that it is 6 N·m {61 kgf·cm, 53 in·lbf} or more.


Remove Intake Oil Shower Pipe

1.Remove using the procedure shown in the figure.
azzdjw00006562

Procedure

Part name
1
Bolt
(See Bolt installation note)
10.5 N·m {107 kgf·m, 93 ft·lbf}
2
Bolt
(See Bolt installation note)
9 N·m {92 kgf·m, 80 ft·lbf}
3
Intake oil shower pipe
—


Bolt installation note

1.Install the bolts using the procedure shown in the figure.
azzdjw00006563

Symbol

Content
Servicing procedure
10.5 N·m {107 kgf·m, 93 ft·lbf}
9 N·m {92 kgf·m, 80 ft·lbf}


Remove Exhaust Oil Shower Pipe

1.Remove using the procedure shown in the figure.
azzdjw00006570

Procedure

Part name
1
Bolt
(See Bolt installation note)
10.5 N·m {107 kgf·m, 93 ft·lbf}
2
Bolt
(See Bolt installation note)
9 N·m {92 kgf·m, 80 ft·lbf}
3
Exhaust oil shower pipe
—


Bolt installation note

1.Install the bolts using the procedure shown in the figure.
azzdjw00006571

Symbol

Content
Servicing procedure
10.5 N·m {107 kgf·m, 93 ft·lbf}
9 N·m {92 kgf·m, 80 ft·lbf}


Remove Electric Variable Valve Timing Motor/Driver

1.Remove in the order indicated in the table.
azzdjw00005444

Step

Part name
1
Connector
—
—
2
Bolt
—
9.5 N·m {97 kgf·cm, 84 in·lbf}
3
Electric variable valve timing motor/driver
—
—
4
Gasket
Replacement part
—


Remove Engine Front Wiring Harness Bracket

1.Remove using the procedure shown in the figure.
azzdjw00006632

Procedure

Part name
1
Clip
—
2
Bolt
—
3
Engine front wiring harness bracket
9.5 N·m {97 kgf·cm, 84 in·lbf}


Remove Water Inlet Pipe

1.Remove using the procedure shown in the figure.
azzdjw00006028

Procedure

Part name
1
Hose
—
2
Bolt
—
3
Water inlet pipe
9.5 N·m {97 kgf·cm, 84 in·lbf}


Remove the engine front cover.

1.Remove using the procedure shown in the figure.
azzdjw00006615

Procedure

Part name

Applicable condition
1
Coupler
Continuous
—
—
—
2
Hose
Continuous
—
—
—
3
Bolt
Continuous
—
—
9.5 N·m {97 kgf·cm, 84 in·lbf}
4
Water outlet
Continuous
—
—
—
5
Gasket
Continuous
—
Replacement part
—
6
Bolt
Continuous
—
—
11 N·m {112 kgf·cm, 97 in·lbf}
7
Ground
Continuous
—
—
—
8
Bolt
Continuous
—
—
23 N·m {2.35 kgf·m, 16.95 ft·lbf}
9
Washer
Continuous
—
—
—
10
Gasket
Continuous
—
Replacement part
—
11
Engine front cover
(See Engine Front Cover Installation Note)
Continuous
TB1217D
—
—


Engine Front Cover Installation Note

Note
• The new engine front cover has two positioning pins that project outward from the engine as shown in the figure.
azzdjw00006619

Symbol

Content
1
POSITIONING PIN
2
Outside of engine
3
Sealing surface side

1.When replacing the engine front cover with a new one, insert two positioning pins into the seal surface side.
azzdjw00006620

Symbol

Content
1
Outside of engine
2
Sealing surface side
3
POSITIONING PIN
4
Wood chip
0—1 mm {0.00—0.03 in}

Caution
• The cylinder head and cylinder block may be cracked if a bolt with a fixed sealant is used.
azzdjw00006622

Symbol

Content
1
Adhering sealant
2
Breakage

2.When the engine front cover mounting bolt is reused, cleanly remove the sealant attached to the bolt.

Caution
• If oil, dirt, and sealant remain on the silicone sealant application surface and the step bead, the silicone sealant will not seal which will cause oil leakage.
azzdjw00006623

Symbol

Content
1
STEP BEAD
2
SILICONE SEALANT APPLICATION SURFACE
3
Engine front cover

3.Cleanly remove oil, dust, sealant, etc. attached to the engine front cover, cylinder head and cylinder block.

4.Degrease the silicone sealant application surface and the step bead.

Note
• The liquid gasket shall be applied without any gap.
• In order to prevent hardening of the liquid gasket, the engine front cover should be brought into close contact with the cylinder block and cylinder head within 10 minutes after application of the liquid gasket. After sealing, complete the installation bolt tightening immediately.
• Do not apply silicone sealant to the step bead.

5.Apply silicone sealant (TB1217D) to the engine front cover according to the directions shown in the figure.
azzdjw00006624

Symbol

Content
1
Bead thickness 2—6 mm {0.1—0.2 in}
2
Bead thickness 4—6 mm {0.16—0.23 in}
3
Bead thickness 4—8 mm {0.2—0.3 in}
10 mm {0.39 in}
32.5 mm {1.28 in}
0.5—1.5 mm {0.02—0.05 in}
90°

Caution
• Apply so as to fill the cylinder head gasket.

6.Apply silicone sealant (TB1217D) to the areas shown in the figure.
azzdjw00006629

7.Attach the engine front cover to the engine.

Note
• In order to prevent the adhesion failure of the liquid gasket in the hole of the drive belt auto tensioner mounting bolt and to prevent the bolt from being unable to be mounted after the liquid gasket has hardened, install an appropriate bolt once in the hole of the drive belt auto tensioner mounting bolt.
azzdjw00006630

Symbol

Content
1
Drive belt auto tensioner mounting bolt holes

8.Prepare a suitable bolt of M8-1.25, 40 mm underneck length.

9.Tighten the No.1 engine front Cover installation bolts in the order shown in the figure.
azzdjw00006631

Symbol

Content
Servicing procedure
23 N·m {2.35 kgf·m, 16.95 ft·lbf}

Caution
• For the number 1 and 8 bolts of the tightening order, install the bolts with washers.


Remove Chain Tensioner No. 1

1.Remove using the procedure shown in the figure.
azzdjw00006189

Procedure

Part name
1
Bolt
(See Bolt removal note)
9.5 N·m {97 kgf·cm, 84 in·lbf}
2
Chain tensioner No.1
(See Chain tensioner installation note)
—


Bolt removal note

1.Rotate the crankshaft clockwise and align the positions of the timing mark and the key to set cylinder No. 1 to top dead center (TDC).
azzdjw00006191

Symbol

Content
1
Cylinder head top surface
2
Pin
3
Timing mark
4
Key

2.While moving the exhaust camshaft back and forth in the direction of the arrows using a wrench on the hexagon part, press down the link plate of the chain tensioner with a precision screwdriver to unlock the plunger.
azzdjw00006192

Symbol

Content
1
Link plate
2
Plunger

3.While holding down the link plate, slowly push the plunger back in the direction shown in the figure.
aaxjjw00026869

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

5.Relieve some of the force from the plunger and move it back and forth 2—3 mm {0.08—0.11 in}.

6.Insert a wire or paper clip with the approx. diameter of 1.5 mm {0.59 in} into the tensioner body at the point where the hole in the link plate overlaps the hole in the tensioner body to secure the link plate and lock the plunger.
azzdjw00006193

Symbol

Content
1
Stopper
2
Link plate

7.Remove the bolts.


Chain tensioner installation note

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

• If a new chain tensioner is used, remove the installed stopper.
azzdjw00006193

Symbol

Content
1
Stopper
2
Link plate

2.Verify the timing chain for looseness and again verify that each sprocket is in place.

3.Rotate the crankshaft clockwise twice and inspect the valve timing.
azzdjw00006194

Symbol

Content
1
Cylinder head top surface
2
Pin
3
Timing mark
4
Key


Remove Tensioner Arm

1.Remove using the procedure shown in the figure.
azzdjw00006215

Procedure

Part name
1
Tensioner arm


Remove Chain Guide No. 1

1.Remove using the procedure shown in the figure.
ac6wzw00000587

Procedure

Part name
1
Bolt
(See Bolt removal note)
9.5 N·m {97 kgf·cm, 84 in·lbf}
2
Bolt
9.5 N·m {97 kgf·cm, 84 in·lbf}
3
Bolt
20 N·m {2.05 kgf·m, 14.75 ft·lbf}
4
Bolt
9.5 N·m {97 kgf·cm, 84 in·lbf}
5
Chain guide No.1
—


Bolt removal note

1.Rotate the crankshaft clockwise to align cylinder No. 1 near the top dead center (TDC).
azzdjw00005679

Symbol

Content
1
Camshaft side
2
Timing chain alignment mark
3
Timing mark
4
Pin
5
Timing chain alignment mark
6
Crankshaft side
7
TDC
8
Timing mark

Note
• If cylinder No. 1 is placed near the top dead center (TDC), the exhaust camshaft will not move (rotate) significantly even if the timing chain is removed, making it easier to install the electric variable valve timing actuator to the camshaft. (When installing the electric variable valve timing actuator to the camshaft in a state where the exhaust camshaft has moved significantly, it is necessary to install it while rotating the exhaust camshaft to loosen the chain.)

2.Assemble several washers and nuts to an M6 bolt (length 35—60 mm {1.4—2.3 in}, entirely threaded type) as shown in the figure.
azzdjw00005680

Symbol

Content
1
Bolt side
2
Nut
3
WASHER (SEVERAL)
24 mm {0.94 in}

3.Insert a precision screwdriver into the lower service hole.
azzdjw00005682

Symbol

Content
1
Lower service hole
2
Precision screwdriver

4.While moving the exhaust camshaft back and forth in the direction of the arrows using a wrench on the hexagon part, press down the link plate of the chain tensioner with a precision screwdriver to unlock the plunger.
azzdjw00005683

Symbol

Content
1
Hexagon Wrench
2
Plunger
3
Timing chain
4
Link plate

5.Rotate the exhaust camshaft clockwise with the plunger unlocked until the timing chain is loosened.
azzdjw00005684

Symbol

Content
1
tiffened
2
Loosened
3
Chain guide (No. 1)
4
Link plate

6.Screw the prepared bolt into the upper service hole by hand until the nut is seated and the tensioner arm is fixed.
azzdjw00005685

Symbol

Content
1
Upper service hole
2
Bolt
3
CONDITION BEFORE CHAIN TENSION RELEASED
4
CONDITION AFTER CHAIN TENSION RELEASED
5
Tensioner arm
6
Rib
7
Upper service hole
8
Engine front cover
9
NUT SEATED
10
BOLT END CONTACTS INSIDE OF RIB
11
CROSS-SECTIONAL VIEW

7.Remove the chain guide No. 1.


Chain guide No. 1 installation note

1.Install the chain guide No. 1.

2.Remove the bolt securing the tensioner arm, and apply tension to the timing chain.

3.Rotate the crankshaft clockwise twice and verify that the valve timing is correct.
azzdjw00005679

Symbol

Content
1
Camshaft side
2
Timing chain alignment mark
3
Timing mark
4
Pin
5
Timing chain alignment mark
6
Crankshaft side
7
TDC
8
Timing mark


Remove Timing Chain

1.Remove using the procedure shown in the figure.
azzdjw00006182

Procedure

Part name
1
Timing chain
(See Timing chain installation note)


Timing chain installation note

1.Verify that the timing mark and the key are in the positions shown in the figure.
azzdjw00006183

Symbol

Content
1
Cylinder head top surface
2
Pin
3
Timing mark
4
Key

2.Install the timing chain while aligning the alignment mark of the timing chain with each sprocket as shown in the figure.
azzdjw00006184

Symbol

Content
1
Timing chain alignment mark of the hydraulic variable valve timing actuator
2
Timing chain alignment mark (orange)
3
Pin
4
Cylinder head top surface
5
Timing mark
6
Crankshaft sprocket timing chain alignment mark
7
Timing chain alignment mark (yellow)


Remove Chain Guide No. 2

1.Remove using the procedure shown in the figure.
azzdjw00006185

Procedure

Part name
1
Bolt
9.5 N·m {97 kgf·cm, 84 in·lbf}
2
Chain guide No.2
—


Remove Chain Tensioner No. 2

1.Remove using the procedure shown in the figure.
azzdjw00006195

Procedure

Part name
1
Bolt
(See Bolt removal note)
9.5 N·m {97 kgf·cm, 84 in·lbf}
2
Chain tensioner No.2
—


Bolt removal note

1.Temporarily assemble the crankshaft pulley lock bolt.

2.Rotate the crankshaft in the direction of the arrow and press in the plunger of chain tensioner No. 2.
azzdjw00006197

3.Insert a wire or paper clip with an approx. diameter of 1.2 mm {0.047 in} at the position where the tensioner body hole overlaps with the chain tensioner No. 2 hole to fix the plunger.

4.Remove chain tensioner No. 2 and tensioner body as a single unit.
azzdjw00006198


Remove Oil Pump Driven Sprocket

1.Remove in the order indicated in the table.
azzezw00000904

Step

Part name
1
Bolt
—
2
Oil pump driven sprocket
55 N·m {5.6 kgf·m, 40.55 ft·lbf}


Oil pump driven sprocket installation note

1.When installing, align the timing chain and sprocket positions.


Remove Oil Pump Chain

1.Remove using the procedure shown in the figure.
azzdjw00006112

Procedure

Part name
1
Oil pump chain
(See Oil Pump Chain Installation Note)


Oil Pump Chain Installation Note

1.Install the oil pump chain using aligning the marks on sprocket and the oil pump chain as shown in the figure.
azzdjw00006113

Symbol

Content
1
Oil pump chain alignment mark
2
Sprocket alignment mark


Remove Chain Guide No. 3

1.Remove using the procedure shown in the figure.
azzdjw00006187

Procedure

Part name
1
Bolt
9.5 N·m {97 kgf·cm, 84 in·lbf}
2
Chain guide No.3
—


Remove Crankshaft Sprocket

1.Remove using the procedure shown in the figure.
azzdjw00006143

Procedure

Part name
1
Crankshaft sprocket


Remove Oil Pump Drive Sprocket

1.Remove using the procedure shown in the figure.
azzdjw00006114

Procedure

Part name
1
Bolt
(See Bolt removal note)
(See Bolt installation note)
55 N·m {5.6 kgf·m, 40.55 ft·lbf}
2
Oil pump drive sprocket
(See Bolt removal note)
—


Bolt removal note

1.Lock the crankshaft pulley lock bolt and remove the oil pump driven sprocket bolt.
azzdjw00006116

Symbol

Content
1
Crankshaft pulley lock bolt
2
Oil pump driven sprocket


Oil pump drive sprocket removal note

1.After removing the oil pump drive sprocket, remove the crankshaft pulley lock bolt.


Bolt installation note

1.Lock the crankshaft pulley lock bolt and install the oil pump driven sprocket bolt.
azzdjw00006117

Symbol

Content
1
Crankshaft pulley lock bolt
2
Oil pump driven sprocket

2.Remove the temporarily assembled crankshaft pulley lock bolt.


Remove Crank Shaft Key

1.Remove using the procedure shown in the figure.
azzdjw00006142

Procedure

Part name
1
Crank shaft key


Add Engine Coolant (Main)

1.Add engine coolant (main) to the top surface of the radiator filler port.
azzdjw00007645

1
Bottle

2.Add engine coolant (main) to the coolant reserve tank up to the FULL line.
azzdjw00007652

1
Bottle

Total coolant amount (reference)

Specification

Capacity
With e-SKYACTIV PHEV
8.6 L {9.1 US qt, 7.6 Imp qt}
Without e-SKYACTIV PHEV
7.0 L {7.4 US qt, 6.2 Imp qt}

3.After the engine coolant (main) is added up to the FULL line of the coolant reserve tank, add an additional 0.26 L {0.27 US qt, 0.23 Imp qt.}.


Perform Engine Coolant (Main) Air Bleeding (With e-SKYACTIV PHEV)

1.Perform the following procedure switch to compulsory engine start mode.

(1)Switch the ignition ON (Ready off) under the following conditions.
• Shift position: P position
• Brake pedal: Not depressed
(2)Depress and release the accelerator pedal 5 times with the brake pedal depressed.
(3)Release the brake pedal and depress the accelerator pedal again the same number of times.
(4)Depress the accelerator pedal the same number of times again while depressing the brake pedal again.
(5)Release the brake pedal.
(6)When the output limit warning light flashes 5 times, the preparation to switch to maintenance mode is competed.
• If the output limit warning light does not flash because the transition to maintenance mode has failed, switch the ignition OFF and verify if the implementation permit conditions are met. If there is no problem, repeat the procedure from Step 1.(See MAINTENANCE MODE.)
Note
• When the preparation for switching to maintenance mode is completed, maintenance mode is not completed even if the ignition is switched OFF.
• The mode returns to the transition preparation completion status by switching the ignition ON again after switching the ignition OFF.
(7)Depress the brake pedal again and switch the main power ON to switch to the desired mode.

2.Perform the engine coolant (main) air bleeding using the following procedure.

(1)Maintain the engine speed at approx. 2,000 rpm for 5 min.
(2)Maintain the engine speed at approx. 2,000 rpm for 10 s.
(3)Maintain idling for 30 s.
(4)Repeat Steps (2) and (3) 5 times.
(5)Maintain the engine speed at approx. 3,000 rpm for 10 s.
(6)Maintain idling for 30 s.
(7)Repeat Steps (5) and (6) 5 times.
(8)Increase the engine speed to approx. 4,000 rpm, and then idle.
(9)Maintain the engine speed at approx. 2,000 rpm for 10 s.
(10)Maintain idling for 30 s.
(11)Repeat Steps (2) to (10) until the air is bled out.

3.Stop the engine and wait until the engine coolant (main) temperature decreases.

4.If the engine coolant (main) level is low, add engine coolant (main) and inspect the coolant amount.


Remove Cooling System Cap

1.Remove in the order indicated in the table.
ac6wzw00000094

Step

Part name
1
Cooling system cap


Inspect For Engine Coolant Leakage

Warning
• A hot engine can cause severe burns. Turn off the engine and wait until it is cool before performing the servicing.
• If the engine cooling system cap is removed when the engine is hot, steam and boiling water may be ejected, causing severe burns or severe injury. Perform the removal of the engine cooling system cap when the engine is cool.
• When removing the engine cooling system cap, cover the engine cooling system cap with a clean cloth and remove it slowly.
Note
• Perform the procedure with the engine cooling system cap removed.

1.Install the radiator cap tester to the filling port.
ampjjw00003132

2.Apply pressure using the radiator cap tester.

Coolant leakage inspection pressure
122.6 kPa {1.250 kgf/cm2, 17.78 psi} [1 min]

3.When pressurizing the radiator, verify that the pressure is maintained.

• If the pressure decreases, repair or replace the location where water is leaking because water leakage can be considered.


Install cooling system cap

1.Install in the order indicated in the table.
ac6wzw00000094

Step

Part name
1
Cooling system cap


Remove Oil Filler Cap

1.Remove in the order indicated in the table.
azzdjw00005599

Step

Part name
1
Oil filler cap


Engine Oil Filling [PYUL]

1.Add engine oil according to the following engine oil capacity (reference).


Engine oil

Item

Specifications

Europe and Taiwan

Except Europe and Taiwan
Engine oil capacity (approx. quantity)
Oil replacement
4.3 L (4.5 US qt, 3.8 Imp qt)
4.3 L (4.5 US qt, 3.8 Imp qt)
Oil and oil filter replacement
4.5 L (4.8 US qt, 4.0 Imp qt)
4.5 L (4.8 US qt, 4.0 Imp qt)
Total (dry engine)
5.1 L {5.4 US qt, 4.5 Imp qt}
5.1 L {5.4 US qt, 4.5 Imp qt}
Recommended engine oil *1
Mazda Original Oil Supra-X
0W-20
API SL or higher
Mazda Original Oil Ultra
5W-30
Alternative engine oil *2
API SN or higher or ACEA A5/B5
0W-20, 5W-30

* 1 :Mazda Original Oils are specially designed/tested for the respective engine. For optimum performance we recommend to use Mazda Original Oils at all times.
* 2 :If you are unable to find a Mazda Original Oil, alternative oils meeting the listed specification may also be used.


Install Oil Filler Cap

1.Install in the order indicated in the table.
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Step

Part name
1
Oil filler cap
(See Oil filler cap installation note)


Oil filler cap installation note

1.Install the oil filler cap.

2.Start the engine and verify that there is no oil leakage.


Inspect Engine Oil Amount

Warning
• A hot engine can cause severe burns. Turn off the engine and wait until it is cool before performing the servicing.
Caution
• Because the engine oil amount may not be measured accurately, inspect the engine oil after warming up the engine (engine oil temperature: approx. 60°C{140 °F} or more) and waiting for 5 min or more when measuring the engine oil amount.
Note
• The viscosity of the engine oil varies according to the engine oil temperature.
• The oil viscosity is high when the engine is cold, and because it takes time for the engine oil to return to the oil pan from each engine part, the engine oil amount cannot be measured accurately.
• The engine oil returns to the oil pan and the engine oil amount can be measured accurately by raising the engine oil temperature to approx. 60 °C{140 °F} or more and waiting for 5 min or more.
• Perform the procedure with the vehicle on a level surface.
• Warm up the engine and allow the engine oil temperature to reach 60 °C{140 °F} or more, then stop the engine and leave it for at least 5 min before performing the procedure.

1.After removing the oil level gauge and wiping off any oil on the gauge, install the oil level gauge again completely.

2.Remove the oil level gauge and verify that the oil level is between the lower and upper limit position on the gauge.
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1
Lower limit position
2
Upper limit position

• If the oil level is the lower limit position or less, perform the engine oil leakage inspection and add engine oil if there is no leakage.
― If the oil level is at the lower limit position, replenish with 1 L{1 US qt, 0.9 Imp qt} of engine oil.
Note
• The engine oil amount indicated between the lower and the upper limit position on the oil level gauge is 1 L {1 US qt, 0.9 Imp qt}.
― If the oil level is less than the lower limit position, add engine oil while verifying the engine oil amount using the oil level gauge. (See ENGINE OIL REPLACEMENT [PYUL].)
• If the oil level is higher than the upper limit position, change the engine oil. (See ENGINE OIL REPLACEMENT [PYUL].)
Note
• Penetration of fuel into engine oil can be considered

3.Securely insert the oil level gauge until the cylinder head cover is seated.


Perform Engine Oil Data Reset

Note
• The body control module (BCM) stores the vehicle status monitors setting values.
• Before replacing the BCM, explain to the customer that the vehicle status monitor will be reset to the initial set values.

1.Select the [Information] button on the home screen.

2.On the information screen, select [Vehicle Status Monitor].

3.Select [Vehicle Maintenance Settings].

4.Select [Reset Oil Change Distance] to perform an engine oil data reset.


Perform Battery Condition Initial Setting (i-Stop Setting)

Caution
• If the engine is started with the hood open, i-stop will not operate until the hood is closed and the engine is restarted. (Not system malfunction) If the engine was started with the hood open, switch the ignition OFF, close the hood, and then restart the engine.
Without M Hybrid Boost (With i-stop)
• (i-stop non operation) If the vehicle is brought in with i-stop not operating, the malfunction cannot be resolved by only performing the battery condition initial setting (i-stop setting). Verify the PID BATT_SOC value and if the value is less than 75%, perform a battery inspection. (See BATTERY INSPECTION.)
• If the [BATT_SOC] has not been verified before disconnecting the negative battery terminal, perform the battery condition initial setting (i-stop setting) after performing the battery inspection.
• Directly after connecting the negative battery terminal, a BATT_SOC value of [ 0%] is displayed because the battery charge status is unstable. (It is necessary to leave vehicle for 6 to 48 hours until battery charge status stabilizes)
Note
T3
• If the diesel particulate filter regeneration control is not performed at a traveled distance of 10 km or less, the PCM performs the diesel particulate filter regeneration control while the setting procedure for the battery condition initial setting (i-stop setting) is performed to stabilize the exhaust gas purification. (Regular regeneration control)
• While the regular regeneration control is performed, a condition in which high engine speed is continued for a specified period of time. (Up to 22 min (depends on engine coolant temperature))

Circle: Applicable—: Not applicable

Purpose

Operation

Without M Hybrid Boost (With i-stop)

T3

PYUL
1. Verify that the BATT_SOC value measured when the vehicle is in the shop is 75% or more.
1. Using the M-MDS, verify that the PID [BATT_SOC] value is 75% or more.
O
O
2. In the following cases, perform a battery inspection. (See BATTERY INSPECTION.)
• [BATT_SOC] value is less than 75%
• [BATT_SOC] value cannot be verified
O
O
2. Have the [BATT_SOC] value determined by the PCM.
1. Disconnect the negative battery terminal and wait for 5 min or more. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
Note
• It is necessary to leave the lead-acid battery undisturbed for or more because the voltage may not be stabilized depending on the battery usage condition and it could cause the PCM to determine the BATT_SOC value incorrectly.
O
O
3. Have the PCM learn the battery condition.
1. Connect the negative battery terminal and wait for 10 s or more. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
O
O
2. Switch the ignition ON (engine off) and wait between 15 s to 60 s.
O
O
3. Press and hold the i-stop OFF switch for approx.10 s.
O
O
4. Verify that the i-stop warning light (amber) illumination changes to the i-stop indicator light (green) flashing.
• If the i-stop warning light (amber) does not turn off, it is possible that the procedure was performed incorrectly, therefore, perform the procedure again from the beginning.
• If the i-stop warning light (amber) flashes, perform a battery inspection. (See BATTERY INSPECTION.)
O
O
5. Switch ignition OFF.
O
O
6. Close the hood.
O
O
4. Perform idle air control learning.
1. Switch the ignition ON (engine on).
—
O
2. Turn off the following systems to which electrical load is applied.
• Lighting systems such as headlights.
• Climate control system
• Rear window defogger
—
O
3. Warm up the engine completely.
—
O
4. Switch the ignition OFF.
—
O
5. Verify the i-stop control settings.
Perform the following procedure from Step 1 to 5 within 25 s.
O
O
1. Switch the ignition ON (engine off) and within 5 s, press and hold the i-stop OFF switch for 3 s or more.
O
O
2. Verify that the i-stop warning light (amber) is on.
O
O
3. Switch the ignition ON (engine on).
O
O
4. Verify that the i-stop warning light (amber) illumination changes to the i-stop indicator light (green) flashing.
• If the i-stop warning light (amber) illuminates or flashes, perform a battery inspection. (See BATTERY INSPECTION.)
O
O
5. Press and hold the i-stop OFF switch for approx. 3 s.
O
O
6. Wait for 30 s while idling (with no electrical load).
O
O
7. Perform engine racing for a minimum 10 times and a maximum 20 times. Then, wait for 30 s while idling (with no electrical load).
• After the flashing i-stop indicator light (green) turns off, switch the ignition OFF.
• If the i-stop indicator light (green) does not turn off, it is possible that there is a problem with the M Hybrid system, therefore, perform an inspection of the M Hybrid system.
Note
• The flashing i-stop indicator light (green) may turn off early and the i-stop control setting verification may be completed early depending on the battery condition.
—
—
8. Maintain the idling condition (with no electrical load) until the i-stop indicator light (green) flashing turns off.
O
O
9. After the flashing i-stop indicator light (green) turns off, switch the ignition OFF.
O
O
6. Perform an i-stop control operation verification.
1. Switch the ignition ON (engine on).
O
O
2. Accelerate to a vehicle speed of 15 km/h in approx. 5 s without operating the steering wheel.
O
O
3. Stop the vehicle.
O
O
4. Verify that the engine stops and restarts by the i-stop control.
O
O
5. Switch the ignition OFF.
O
O


Perform Power Liftgate Initialization

Note
• If the negative battery terminal is disconnected with the power liftgate fully opened or half-open, the auto open/close operation of the power liftgate is disabled.

1.Close the power liftgate manually.


Initialize Power Outer Mirror Retract/Return Function

Note
• After reconnecting the negative battery terminal, the power outer mirror retract/return position recognized by the door-electrical supply unit may differ from the power outer mirror retract/return position of the vehicle. For this reason, it may be necessary to initialize the power outer mirror retract/return function.

Power outer mirrors are in returned position

1.Switch the ignition ON (engine off)/switch the main power ON (READY off).

2.Press the power outer mirror retract/return switch to retract the power outer mirrors.

3.Press the power outer mirror retract/return switch again to return the power outer mirrors.

4.Switch the ignition OFF/switch the main power OFF.


Power outer mirrors are in retracted position

1.Switch the ignition ON (engine off)/switch the main power ON (READY off).

2.Press the power outer mirror retract/return switch 2 times to return the power outer mirrors.

3.Switch the ignition OFF/switch the main power OFF.


Perform Windshield Wiper Arm And Blade Initial Setting

• Refer to the troubleshooting manual for the procedure for using the M-MDS.

Perform 360° View Monitor System Aiming

• Refer to the troubleshooting manual for the procedure for using the M-MDS. (Refer to [360° VIEW MONITOR SYSTEM AIMING] in the troubleshooting manual.)

Perform Radar Sensor (Front) Aiming (Without Radar Sensor (Front Side))

• Refer to the troubleshooting manual for the procedure for using the M-MDS. (Refer to [RADAR SENSOR (FRONT) AIMING] in the troubleshooting manual.)

Simultaneously Aim Radar Sensor (Front) And (Front Side) (With Radar Sensor (Front Side))

Caution
• When repainting the front bumper face, do not repaint the radar emitting area shown in the figure (same as right side) because the radar sensor (front side) aiming may not be performed correctly.
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Symbol

Content
Radar emitting area
118 mm {4.65 in}
220 mm {8.66 in}
55 mm {2.2 in}
35 mm {1.4 in}
157 mm {6.18 in}
100 mm {3.94 in}

Note
• Refer to the troubleshooting manual for the procedure for using the M-MDS. (Refer to [RADAR SENSOR (FRONT) AND (FRONT SIDE) SIMULTANEOUS AIMING] in the troubleshooting manual.)