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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.
  • Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the "Fuel Line Safety Procedure" to prevent the fuel from spraying.
    • Fuel may cause irritation if it comes in contact with skin and eyes.
    • If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
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 transmission component removal/installation from the lower side of the vehicle after removing the front crossmember component.
  1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. Remove the front wheels and tires. (See GENERAL PROCEDURES (SUSPENSION) .)
  3. Remove the front mudguard No. 1 and No. 2. (See FRONT MUDGUARD REMOVAL/INSTALLATION .)
  4. Remove the front splash shield No. 1 and No. 2. (See FRONT SPLASH SHIELD No. 1 REMOVAL/INSTALLATION .) (See FRONT SPLASH SHIELD No. 2 REMOVAL/INSTALLATION .)
  5. Remove the front under cover. (See FRONT UNDER COVER REMOVAL/INSTALLATION .)
  6. Remove the front crossmember under cover. (See FRONT CROSSMEMBER UNDER COVER REMOVAL/INSTALLATION .)
  7. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  8. Drain the ATF. (AT) (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [SJ6A-EL] .)
  9. Disconnect the connectors shown in the figure and set the wiring harness aside.
    G11275796Courtesy of MAZDA MOTORS CORP.
  10. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION .)
  11. Remove the following intake air system related parts as a single unit. (With resonance chamber No. 2) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
    • Resonance chamber No. 2
    • Resonance duct
    • Air intake hose No. 1
    • Air intake hose No. 2
    • Air intake hose No. 3
  12. Remove the air cleaner, air hose and resonance chamber No. 1 as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  13. Disconnect the upper radiator hose, heater hose and secure the upper radiator hose, heater hose using wire or rope so that it is out of the way.
    G11275797Courtesy of MAZDA MOTORS CORP.
  14. Remove the bolt shown in the figure and set the cooler pipe, heater hose and bracket aside.
    Fig 1: Cooler Pipe, Heater Hose, Bracket And Bolt With Torque Specification
    G11275798Courtesy of MAZDA MOTORS CORP.
  15. Disconnect the heater hose from the water outlet component side.
  16. Disconnect the lower radiator hose from the thermostat side. (See THERMOSTAT REMOVAL/INSTALLATION .)
  17. Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  18. Remove the PCM and PCM bracket component. (See PCM REMOVAL/INSTALLATION .)
  19. Set aside the engine wiring harness on the engine.
    G11275799Courtesy of MAZDA MOTORS CORP.
  20. Remove the bolt and clips shown in the figure and set the wiring harness aside.
    Fig 2: Wiring Harness, Clips And Bolt With Torque Specification
    G11275800Courtesy of MAZDA MOTORS CORP.
  21. Disconnect the ground cable shown in the figure.
    Fig 3: Ground Cable, Clip And Bolt With Torque Specification
    G11275801Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION .)
  23. Disconnect the evaporative hose. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  24. Disconnect the fuel hose from the engine side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  25. Disconnect the selector lever. (AT) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL] .)
  26. Remove the shift lever. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [M66M-D] .)
  27. Remove the clutch release cylinder with the pipe still connected. (MT) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION .)
  28. Disconnect the oil hoses from the radiator using the following procedure: (AT)
    NOTE:
    • ATF drains from the radiator and oil hoses when the oil hoses are disconnected.
    1. Place a container under the vehicle to collect drained ATF.
    2. Disconnect the oil hoses from the radiator.
    3. Secure the oil hoses using rope or equivalent with the hose ends facing upward so that ATF does not drain.
  29. Remove in the order indicated in the table.
  30. Install in the reverse order of removal.
  31. Refill the ATF. (AT) (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [SJ6A-EL] .)
  32. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  33. Start the engine, and inspect and adjust the following:
    • Front wheel alignment (See FRONT WHEEL ALIGNMENT .)
    • Leakage of engine oil, engine coolant, ATF (AT) 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.
    Fig 4: Engine Components With Torque Specification
    G13487951Courtesy of MAZDA MOTORS CORP.
    COMPONENT DESCRIPTION

    1 Member bracket (MT)
    (See POWER PLANT FRAME REMOVAL [M66M-D] .)
    (See POWER PLANT FRAME INSTALLATION [M66M-D] .)
    2 Tunnel member
    (See POWER PLANT FRAME REMOVAL [M66M-D] .)
    (See POWER PLANT FRAME INSTALLATION [M66M-D] .)
    3 TWC
    (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
    (See TWC Installation Note .)
    4 Front crossmember component
    (See Front Crossmember Component Removal/Installation Note .)
    5 Propeller shaft
    (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
    6 Power plant frame
    (See POWER PLANT FRAME REMOVAL [M66M-D] .)
    (See POWER PLANT FRAME INSTALLATION [M66M-D] .)
    7 Engine, transmission
    (See Engine, Transmission Removal/Installation Note .)
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