Mazdamanuals.com

TURBOCHARGER WITH VARIABLE TURBINE GEOMETRY REMOVAL/INSTALLATION [SKYACTIV-D 1.8]

Home  id0113q9707500

Replacement Part

Warning

•  A hot engine and intake air system can cause severe burns. Turn off the engine and wait until they are cool before removing the intake-air system.

Caution

•  If the intake-air system, exhaust system, or the engine is damaged, fragments of the damaged part may be remaining in the intake-air system or exhaust system. If the turbocharger is replaced without removing fragments of the damaged part, it could cause turbocharger damage or malfunction. Before replacing the turbocharger, verify that no fragments remain in the parts to be reused.

•  Perform exhaust gas temperature sensor removal/installation only when inspection or replacement is required, such as when DTCs for the sensor are displayed, because it may cause exhaust gas leakage. If the exhaust gas temperature sensor is removed once, always verify that there is no exhaust gas leakage after reinstallation.

Note

•  When removing or replacing the variable geometry turbocharger, perform the “Operation After Replacing or Removal/Installation Turbocharger”.

Operation After Replacing or Removal/Installation Turbocharger

1.  If the turbocharger is replaced or removed/installed, perform the following procedure.

STEP	ACTION	PAGE/CONDITION
1	Switch the ignition off.	—
2	Wait for 30 s.	—
3	Start the engine.	—
4	Maintain the engine idling condition for 10 s.	—
5	Switch the ignition off.	—
6	Wait for 30 s.	—
7	Perform KOER self-test procedure.	(See DTC INSPECTION.)

Turbocharger With Variable Turbine Geometry Removal/Installation

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

3.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 1.8].)

4.  Remove the following parts: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

•  Fresh-air duct

•  Air cleaner

•  Air hose

•  Air inlet pipe

5.  Remove the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

6.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

•  Turbocharger air inlet hose

•  Blow-by heater

•  Breather hose

7.  Remove the turbocharger air outlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

8.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)

9.  Remove the catalytic converter (DPF). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

10.  Remove the catalytic converter (oxidation catalyst/NOx strage catalyst). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8] .)

11.  Remove in the order shown in the figure.

12.  Install in the reverse order of removal.

13.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 1.8].)

14.  Perform the following procedure.

When newly replacing Turbocharger With Variable Turbine Geometry

•  Replace the engine oil. (See ENGINE OIL REPLACEMENT [SKYACTIV-D 1.8].)

When installing a removed Turbocharger With Variable Turbine Geometry

•  Inspect the engine oil level. (See ENGINE OIL LEVEL INSPECTION [SKYACTIV-D 1.8].)

ac3wzw00005085

1	Heater hose
2	Vacuum hose (See Vacuum hose installation note.)
3	Turbocharger actuator connector
4	Turbocharger bracket
5	Insulator
6	Insulator
7	Oil main pipe
8	Oil return pipe No.1
9	Oil return hose (See Oil Return Hose Installation Note.)
10	Oil return pipe No.2
11	Turbocharger with variable turbine geometry (See Operation After Replacing or Removal/Installation Turbocharger.)
12	Exhaust gas temperature sensor No.1 (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)
13	A/F sensor (See AIR FUEL RATIO (A/F) SENSOR DATA RESET [SKYACTIV-D 1.8].)
14	Exhaust gas temperature sensor No.2 (See EXHAUST GAS TEMPERATURE SENSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Oil Return Hose Installation Note

1.  Install the oil return hose as shown in the figure.

ac3wzw00004684

Vacuum hose installation note

1.  Install the vacuum hose as shown in the figure.

ac3wzw00004685