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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 transaxle component removal/installation from below the vehicle.
  1. Disconnect the negative battery terminal. (Refer to NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. Remove the front under cover No. 1 and No. 2. (Refer to FRONT UNDER COVER No. 1 REMOVAL/INSTALLATION .) (Refer to FRONT UNDER COVER No. 2 REMOVAL/INSTALLATION .)
  3. Remove the front splash shield. (Refer to FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
  4. Drain the engine coolant. (Refer to ENGINE COOLANT REPLACEMENT .)
  5. Drain the ATF. (Refer to AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL] .)
  6. Drain the transfer oil. (AWD) (Refer to TRANSFER OIL REPLACEMENT [GW6AX-EL] .)
  7. Remove the front wheels and tires. (Refer to WHEEL AND TIRE REMOVAL/INSTALLATION .)
  8. Remove the plug hole plate. (Refer to PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  9. Remove the air cleaner, air hose and fresh air duct as a single unit. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  10. Remove the bolt, nut, clip and connector shown in the figure, and set the wiring harness aside.
    Fig 1: Identifying Wiring Harness Bolt With Torque Specifications
    G10946629Courtesy of MAZDA MOTORS CORP.
  11. Remove the battery and battery tray. (Refer to BATTERY REMOVAL/INSTALLATION .)
  12. Remove the air inlet pipe. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  13. Remove the turbocharger air outlet pipe and charge air cooler inlet hose. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  14. Remove the charge air cooler outlet pipe and charge air cooler outlet hose as a single unit. (Refer to INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  15. Disconnect the selector cable. (Refer to AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
  16. Disconnect the brake vacuum hose. (Refer to VACUUM HOSE REMOVAL/INSTALLATION .)
  17. Disconnect the clip shown in the figure.
    Fig 2: Identifying Evaporative And Fuel Hose Clips
    G10946630Courtesy of MAZDA MOTORS CORP.
  18. Disconnect the evaporative hose. (Refer to PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  19. Disconnect the fuel hose. (Refer to QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  20. Disconnect the upper radiator hose.
    Fig 3: Identifying Upper Radiator Hose Clip
    G10946631Courtesy of MAZDA MOTORS CORP.
  21. Remove the lower radiator hose and pipe component using the following procedure:
    1. Disconnect the lower radiator hose shown in the figure.
      Fig 4: Identifying Lower Radiator Hose Clip
      G10946632Courtesy of MAZDA MOTORS CORP.
    2. Disconnect the connector and clip shown in the figure. (U.S.A. and CANADA)
      Fig 5: Identifying Lower Radiator Hose Clip And Connector
      G10946633Courtesy of MAZDA MOTORS CORP.
    3. Disconnect the clip shown in the figure. (Except U.S.A. and CANADA)
      Fig 6: Identifying Lower Radiator Hose Clip
      G10946634Courtesy of MAZDA MOTORS CORP.
    4. Remove the lower radiator hose and pipe component.
      Fig 7: Identifying Lower Radiator Hose Clip
      G10946635Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the heater hoses.
    Fig 8: Identifying Heater Hose Clip
    G10946636Courtesy of MAZDA MOTORS CORP.
  23. Remove the generator drive belt. (Refer to DRIVE BELT REMOVAL/INSTALLATION .)
  24. Disconnect the water hose from water-cooled oil cooler.
    Fig 9: Identifying Water Hose Clip
    G10946637Courtesy of MAZDA MOTORS CORP.
  25. Disconnect the oil hoses from radiator. (if equipped) (Refer to OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL] .)
  26. 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. (Refer to A/C COMPRESSOR REMOVAL/INSTALLATION .)
  27. Remove the TWC installation nuts (WU-TWC side) and secure the TWC using wire or rope so that it is out of the way (2WD). (Refer to EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  28. Remove the TWC. (AWD) (Refer to EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  29. Remove the propeller shaft. (AWD) (Refer to PROPELLER SHAFT REMOVAL/INSTALLATION .)
  30. Disconnect the front drive shaft (LH) from the transaxle side and set the drive shaft (LH) out of the way. (Refer to FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  31. Disconnect the front drive shaft (RH) from the transaxle side and set the drive shaft (RH) out of the way. (2WD) (Refer to FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  32. Remove the front drive shaft (RH). (AWD) (Refer to FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  33. Remove the bolt and set the ground cable aside.
    Fig 10: Identifying Ground Cable Bolt With Torque Specifications
    G10946638Courtesy of MAZDA MOTORS CORP.
  34. Remove in the order indicated in the table.
  35. Install in the reverse order of removal.
  36. Refill the transfer oil. (AWD) (Refer to TRANSFER OIL REPLACEMENT [GW6AX-EL] .)
  37. Refill the ATF. (Refer to AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL] .)
  38. Refill the engine coolant. (Refer to ENGINE COOLANT REPLACEMENT .)
  39. Start the engine, and inspect and adjust the following:
    • Front wheel alignment (Refer to 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. (Refer to 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.

    2WD 

    Fig 11: Engine Mount Components With Torque Specifications (1 Of 2)
    G10946639Courtesy of MAZDA MOTORS CORP.
    COMPONENT DESCRIPTION

    1 Bracket plate
    (See Engine Mount Installation Note .)
    2 No. 1 engine mount rubber, front crossmember component
    (See No. 1 Engine Mount Rubber, Front Crossmember Component Removal Note .)
    (See Engine Mount Installation Note .)
    3 No. 1 engine mount bracket
    (See Engine Mount Installation Note .)
    4 No. 4 engine mount bracket
    (See No. 3 Engine Mount, No. 4 Engine Mount Bracket Removal Note .)
    (See Engine Mount Installation Note .)
    5 No. 3 engine mount
    (See No. 3 Engine Mount, No. 4 Engine Mount Bracket Removal Note .)
    (See Engine Mount Installation Note .)
    6 Engine, transaxle

    AWD 

    Fig 12: Engine Mount Components With Torque Specifications (2 Of 2)
    G10946640Courtesy of MAZDA MOTORS CORP.
    COMPONENT DESCRIPTION

    1 Bracket plate
    (See Engine Mount Installation Note .)
    2 No. 1 engine mount rubber, front crossmember component
    (See No. 1 Engine Mount Rubber, Front Crossmember Component Removal Note .)
    (See Engine Mount Installation Note .)
    3 No. 4 engine mount bracket
    (See No. 3 Engine Mount, No. 4 Engine Mount Bracket Removal Note .)
    (See Engine Mount Installation Note .)
    4 No. 3 engine mount
    (See No. 3 Engine Mount, No. 4 Engine Mount Bracket Removal Note .)
    (See Engine Mount Installation Note .)
    5 Engine transaxle
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