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Engine Installation

WARNING: This page is about a different car, the 2018 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • When removing/installing the engine, verify that the engine and transaxle are securely supported Otherwise, the engine may fall off and cause serious injury or death, and damage to the vehicle.
CAUTION:
  • Slots have been adopted for the No. 3 engine mount and No. 4 engine mount bracket installation holes. Tighten the installation bolts and nuts so that they are centered on the slots. Otherwise, engine noise or vibration could increase.
NOTE:
  • Retighten the engine front cover and transaxle stud bolts when the nuts of No. 3 engine mount and No. 4 engine mount bracket are loosened.
  1. Tighten the engine front cover stud bolts.
    Fig 1: Engine Front Cover Stud Bolts
    G11436692Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    7-13 Nm {72-132 kgf.cm, 62-115 in.lbf}

  2. Tighten the transaxle stud bolts.
    Fig 2: Transaxle Stud Bolts
    G12228050Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    15-25 N.m {1.6-2.5 kgf.m, 12-18 ft.lbf}

    CAUTION:
    • When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent the deformation of the oil pan and damage of the transaxle.
  3. Secure the engine and transaxle using a commercially available engine lifter.
    Fig 3: Securing Engine And Transaxle Using Engine Lifter
    G09074309Courtesy of MAZDA MOTORS CORP.
  4. Return the engine and transaxle to their original positions.
  5. Temporarily tighten the No. 3 engine mount installation bolts and nuts using the following procedure:
    1. Temporarily tighten the bolts shown in the figure below so that they are centered on the No. 3 engine mount slots.
      Fig 4: Bolts On No. 3 Engine Mount Slots
      G12228052Courtesy of MAZDA MOTORS CORP.
    2. Temporarily tighten the nuts shown in the figure below so that the stud bolts of the engine front cover are centered on the No. 3 engine mount slots.
    • If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the engine, and temporarily tighten the installation nuts.
    Fig 5: Aligning Stud Bolts With Center Of Slots
    G12228053Courtesy of MAZDA MOTORS CORP.
  6. Temporarily tighten the No. 4 engine mount bracket installation bolt and nuts using the following procedure:
    1. Temporarily tighten the bolt shown in the figure below.
      Fig 6: Bolt And No 4 Engine Mount Bracket
      G11436697Courtesy of MAZDA MOTORS CORP.
    2. Temporarily tighten the nuts shown in the figure below so that they are centered on the No. 4 engine mount bracket slots.
    • If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the transaxle, and temporarily tighten the installation nuts.
    Fig 7: Aligning Stud Bolts With Center Of Slots
    G12228055Courtesy of MAZDA MOTORS CORP.
  7. Install the A/C compressor. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T] .)
  8. Connect the heater hoses.
    Fig 8: Heater Hoses, Water Pump Pulley And Clip
    G11436677Courtesy of MAZDA MOTORS CORP.
  9. Install the charge air cooler outlet pipe and charge air cooler outlet hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  10. Install the No. 1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
  11. Tighten the No. 3 engine mount installation bolts and nuts in the order shown in the figure below.
    NOTE:
    • At this stage, only temporarily tighten the No. 1 engine mount rubber, do not tighten it completely.
    Fig 9: Engine Mount Installation Bolts And Nuts Tightening Sequence
    G11436702Courtesy of MAZDA MOTORS CORP.
    TIGHTENING TORQUE SPECIFICATION

    Installation position Tightening torque
    1 76-95 N.m {7.8-9.6 kgf.m, 57-70 ft-lbf}
    2 82-95 N.m {8.4-9.6 kgf.m, 61-70 ft.lbf}
    3 49-65 N.m {5.0-6.6 kgf.m, 68-85 ft.lbf}
  12. Tighten the No. 4 engine mount bracket installation bolts and nuts in the order shown in the figure below.
    Fig 10: No 4 Engine Mount Bracket Installation Bolt And Nuts Tightening Sequence
    G11436703Courtesy of MAZDA MOTORS CORP.
    TIGHTENING TORQUE SPECIFICATION

    Installation position Tightening torque
    1, 2, 3 92-116 N.m {9.4-11 kgf.m, 68-85 ft.lbf}
    4 81-99 N.m {8.3-10 kgf.m, 60-73 ft.lbf}
  13. Tighten the No. 1 engine mount rubber installation bolts.
    Fig 11: No. 1 Engine Mount Rubber Installation Bolts
    G12228059Courtesy of MAZDA MOTORS CORP.
    TIGHTENING TORQUE SPECIFICATION

    Installation position Tightening torque
    1 141-172 N.m {15-17 kgf.m, 104-126 ft.lbf}
    2 130-164 N.m {14-16 kgf.m, 96-120 ft.lbf}
  14. Install the front drive shafts. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  15. Install the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  16. Install the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  17. Connect the oil hoses to the radiator, (if equipped) (See (See OIL COOLER REMOVAL/INSTALLATION .) .)
  18. Connect the lower radiator hose using the following procedure:
    1. Connect the lower radiator hose to the radiator.
      Fig 12: Connecting Lower Radiator Hose And Clip
      G11436676Courtesy of MAZDA MOTORS CORP.
    2. Install the clip shown in the figure below.
      Fig 13: Lower Radiator Hose And Clip
      G11436675Courtesy of MAZDA MOTORS CORP.
    3. Connect the lower radiator hose to the engine side.
    Fig 14: Connecting Lower Radiator Hose To Engine Side
    G11436673Courtesy of MAZDA MOTORS CORP.
  19. Install the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  20. Install the wiring harness bracket using the following procedure:
    1. Tighten the bolts shown in the figure below.
      Fig 15: Wiring Harness Bracket
      G12228047Courtesy of MAZDA MOTORS CORP.

      Tightening torque 

      8-10 N.m {82-101 kgf.cm, 71-88 in.lbf}

    2. Tighten the nut shown in the figure below.
      Fig 16: Cooler Hose And Nut
      G12228046Courtesy of MAZDA MOTORS CORP.

      8-10 N.m {82-101 kgf.cm, 71-88 in.lbf}

  21. Install the PCM component using the following procedure:
    1. Return the PCM component that was set aside to its original position.
    2. Temporarily tighten the bolt shown in the figure below.
      Fig 17: PCM Component Bolt
      G12228065Courtesy of MAZDA MOTORS CORP.
    3. Tighten the PCM component installation bolts in the order shown in the figure below.
      Fig 18: PCM Component Installation Bolts Tightening Sequence
      G12228066Courtesy of MAZDA MOTORS CORP.

      Tightening torque 

      9-10 N.m {92-101 kgf.cm, 80-88 in.lbf}

    4. Install the wiring harness protector and connector.
      Fig 19: Wiring Harness Protector And Connector
      G12228043Courtesy of MAZDA MOTORS CORP.

      Tightening torque 

      9-12 N.m {92-122 kgf.cm, 80-106 in.lbf}

    5. Connect the PCM connector (140-pin side) to the PCM. (See PCM REMOVAL/INSTALLATION .)
  22. Connect the ground cable shown in the figure below.
    Fig 20: Connecting Ground Cable (LH)
    G12228041Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    9-12 N.m {92-122 kgf.cm, 80-106 in.lbf}

    Fig 21: Connecting Ground Cable (RH)
    G12228042Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    9-12 N.m {92-122 kgf.cm, 80-106 in.lbf}

  23. Connect the upper radiator hose and water hose.
    Fig 22: Connecting Upper Radiator Hose And Water Hose
    G12228035Courtesy of MAZDA MOTORS CORP.
  24. Connect the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  25. Connect the evaporative hose. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  26. Install the clip shown in the figure below.
    Fig 23: Fuel Hose, Clip And Evaporative Hose
    G11436671Courtesy of MAZDA MOTORS CORP.
  27. Connect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T] .)
  28. Connect the selector cable. (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
  29. Install the turbocharger air outlet pipe and charge air cooler inlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  30. Install the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  31. Install the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.5T] .)
  32. Connect the wiring harness shown in the figure below.
    Fig 24: Connecting Wiring Harness
    G12228072Courtesy of MAZDA MOTORS CORP.
  33. Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  34. Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  35. Refill the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .)
  36. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  37. Start the engine, and inspect and adjust the following:
    • Front wheel alignment (See FRONT WHEEL ALIGNMENT .)
    • Leakage of engine oil, engine coolant, ATF, 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.
  38. Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
  39. Install 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 .)
  40. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
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