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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 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: Wiring Harness Bolts And Nut With Torque Specification
    G13149138Courtesy 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. (See FRONT 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 [C66M-R] (MTX).) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [EW6A-EL/EW6AX-EL] (ATX).)
  10. Drain the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [EW6AX-EL] .)
  11. Remove the front wheels and tires. (See GENERAL PROCEDURES (BRAKE) .)
  12. Disconnect the selector cable. (ATX) (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
  13. Disconnect the control cable. (MTX) (See MANUAL TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION [C66M-R].)
  14. Remove the clutch release cylinder with the pipe still connected. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R].)
  15. Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION .)
  16. Disconnect evaporative hose No. 1 from the engine side. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  17. Disconnect the fuel hose from the engine side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  18. Disconnect the upper radiator hose using the following procedure.
    1. Remove the bracket shown in the figure from the throttle body.
      Fig 2: Throttle Body Bracket Bolt With Torque Specification
      G13149139Courtesy of MAZDA MOTORS CORP.
    2. Disconnect the upper radiator hose from the engine side.
  19. Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION .)
  20. Disconnect the lower radiator hose from the engine side. (Without coolant control valve)
  21. Disconnect the lower radiator hose from the radiator. (With coolant control valve)
  22. Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  23. 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 .)
  24. Remove the TWC installation nuts (exhaust manifold side) and secure the TWC using wire or rope so that it is out of the way. (2WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  25. Remove the TWC. (AWD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  26. Remove the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
  27. Disconnect the front drive shaft (LH) from the transaxle side and set the drive shaft (LH) out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  28. Disconnect the front drive shaft (RH) from the transaxle side and set the drive shaft (RH) out of the way. (2WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  29. Remove the front drive shaft (RH). (AWD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  30. Remove the bolt and clips, and set the ground cable aside.

    RH 

    Fig 3: Ground Cable Bolt With Torque Specification (RH)
    G13149140Courtesy of MAZDA MOTORS CORP.

    LH 

    Fig 4: Ground Cable Bolt With Torque Specification (LH)
    G13149141Courtesy of MAZDA MOTORS CORP.
  31. Remove in the order indicated in the table.
  32. Install in the reverse order of removal.
  33. Refill the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [EW6AX-EL] .)
  34. Refill the transaxle oil (MTX) or ATF (ATF). (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R] (MTX).) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [EW6A-EL/EW6AX-EL] (ATX).)
  35. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  36. 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.

2WD 

Fig 5: Engine Components With Torque Specification (2WD)
G13149142Courtesy of MAZDA MOTORS CORP.
COMPONENT DESCRIPTION

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

AWD 

Fig 6: Engine Components With Torque Specification (AWD)
G13149143Courtesy of MAZDA MOTORS CORP.
COMPONENT DESCRIPTION

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