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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. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  2. 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 .)
  3. Remove the front splash shield. (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
  4. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  5. Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL] .)
  6. Drain the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [GW6AX-EL] .)
  7. Remove the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  8. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  9. Remove the air cleaner, air hose and fresh air duct as a single unit. (See 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: Wiring Harness, Connector, Clip, Nut And Bolt With Torque Specification
    G11436670Courtesy of MAZDA MOTORS CORP.
  11. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION .)
  12. Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  13. Remove the turbocharger air outlet pipe and charge air cooler inlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  14. Remove the charge air cooler outlet pipe and charge air cooler outlet hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  15. Disconnect the selector cable. (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION .)
  16. Disconnect the brake vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION .)
  17. Disconnect the clip shown in the figure.
    G11436671Courtesy of MAZDA MOTORS CORP.
  18. Disconnect the evaporative hose. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  19. Disconnect the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  20. Disconnect the upper radiator hose.
    G11436672Courtesy 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.
      G11436673Courtesy of MAZDA MOTORS CORP.
    2. Disconnect the connector and clip shown in the figure. (U.S.A. and CANADA)
      G11436674Courtesy of MAZDA MOTORS CORP.
    3. Disconnect the clip shown in the figure. (Except U.S.A. and CANADA)
      G11436675Courtesy of MAZDA MOTORS CORP.
    4. Remove the lower radiator hose and pipe component.
      G11436676Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the heater hoses.
    G11436677Courtesy of MAZDA MOTORS CORP.
  23. Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  24. Disconnect the water hose from water-cooled oil cooler.
    G11436678Courtesy of MAZDA MOTORS CORP.
  25. Disconnect the oil hoses from radiator. (if equipped) (See 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. (See 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). (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  28. Remove the TWC. (AWD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  29. Remove the propeller shaft. (AWD) (See 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. (See 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) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  32. Remove the front drive shaft (RH). (AWD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  33. Remove the bolt and set the ground cable aside.
    Fig 2: No. 4 Engine Mount Bracket, Ground Cable And Bolt With Torque Specification
    G11436679Courtesy of MAZDA MOTORS CORP.
  34. Remove in the order indicated in the table.

    2WD 

    Fig 3: Engine Components With Torque Specification (2WD)
    G13569467Courtesy of MAZDA MOTORS CORP.
    PART 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 4: Engine Components With Torque Specification (AWD)
    G13444560Courtesy of MAZDA MOTORS CORP.
    PART 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
  35. Install in the reverse order of removal.
  36. Refill the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [GW6AX-EL] .)
  37. Refill the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL] .)
  38. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  39. 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.
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