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Engine Removal/Installation: Notes

WARNING:
  • A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.
  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION .)
CAUTION:
  • Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.
  • Applying excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the electric variable valve timing motor/driver may cause a malfunction. When servicing, be careful not to apply excessive force to the electric variable valve timing motor/driver using other parts or tools.
NOTE:
  • Perform the engine and transaxle component removal/installation from below the vehicle.
  1. Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION .)
  2. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  3. Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  4. Remove the bolts, nut and connector shown in the figure, and set the wiring harness aside.
    Fig 1: Removing/Installing Bolts, Nut And Connector With Torque Specification
    G11550055Courtesy of MAZDA MOTORS CORP.
  5. Remove the battery tray and PCM component. (See BATTERY REMOVAL/INSTALLATION .)
  6. Remove the front under cover No. 1 and No. 2. (See FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .) (See FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  7. Remove the front splash shield No. 1. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
  8. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  9. Drain the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT .) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .)
  10. Remove the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  11. Disconnect the selector cable. (ATX) (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
  12. Disconnect the control cable. (MTX) (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
  13. Remove the clutch release cylinder with the pipe still connected. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
  14. Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION .)
  15. Disconnect evaporative hose No. 1 from the engine side. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  16. Disconnect the fuel hose from the engine side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  17. Disconnect the upper radiator hose. (See COOLING FAN MOTOR REMOVAL/INSTALLATION .)
  18. Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION .)
  19. Disconnect the lower radiator hose. (See RADIATOR REMOVAL/INSTALLATION .)
  20. Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  21. Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (With A/C) (See A/C COMPRESSOR REMOVAL/INSTALLATION .)
  22. Remove the TWC installation nuts (exhaust manifold side) and secure the TWC using wire or rope so that it is out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  23. Disconnect the drive shaft from the transaxle side and set the drive shaft out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  24. Remove the bolt and clips, and set the ground cable aside.
    Fig 2: Removing/Installing Bolts And Clips With Torque Specification (1 Of 2)
    G09785228Courtesy of MAZDA MOTORS CORP.
    Fig 3: Removing/Installing Bolts And Clips With Torque Specification (2 Of 2)
    G09785229Courtesy of MAZDA MOTORS CORP.
  25. Remove in the order indicated in the table.
  26. Install in the reverse order of removal.
  27. Refill the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT .) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .)
  28. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  29. Start the engine, and inspect and adjust the following:
    • Front wheel alignment (See FRONT WHEEL ALIGNMENT .)
    • Leakage of engine oil, engine coolant, ATF (ATX), transaxle oil (MTX), and fuel.
    • Runout and contact of pulley and belt.
    • Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP .)
    • Engine-driven accessories operation.
    NOTE:
    • If the engine is overhauled and assembled to the vehicle, perform a road test to verify that there is no abnormal vibration and noise.
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