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Engine Removal/Installation - 2.3L

WARNING: This page is about a different car, the 2005 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in Neutral, position it on a hoist. See LIFTING .
  2. Relieve the fuel pressure. See FUEL PRESSURE RELIEF .
  3. Disconnect the negative battery cable.
  4. Recover the A/C system. See A/C REFRIGERANT SYSTEM TESTS .
  5. Drain the engine cooling system. See ENGINE COOLANT REPLACEMENT - 2.3L .
  6. Drain the engine oil.
  7. Remove the hood.
  8. Remove the accelerator control splash shield.
    Fig 1: Removing Accelerator Control Splash Shield Nuts - With Torque Specification
    G03728203Courtesy of MAZDA MOTORS CORP.
  9. Remove the air cleaner tube. See AIR CLEANER OUTLET PIPE REMOVAL/INSTALLATION - 2.3L .
  10. Remove the upper radiator hose.
    Fig 2: Removing Upper Radiator Hose
    G03728204Courtesy of MAZDA MOTORS CORP.
  11. Remove the lower radiator hose.
    Fig 3: Removing Lower Radiator Hose
    G03728205Courtesy of MAZDA MOTORS CORP.
  12. Remove the fan and shroud. See ELECTRIC COOLING FAN REMOVAL/INSTALLATION - 2.3L .
  13. Disconnect the powertrain control module (PCM) electrical connector. Remove the retaining nut on the harness clamp. Position the harness on the engine.
    Fig 4: Disconnecting Powertrain Control Module Electrical Connector - With Torque Specifications
    G03728206Courtesy of MAZDA MOTORS CORP.
  14. Remove the ground stud for the PCM.
    Fig 5: Removing Ground Stud For PCM
    G03728207Courtesy of MAZDA MOTORS CORP.
  15. Remove the heater hose assembly.
    1. Disconnect the heater water hoses at the bulkhead.
    2. Disconnect the vacuum hose.
    3. Disconnect the heater water hoses at the engine and remove the assembly.
      Fig 6: Removing Heater Hose Assembly
      G03728208Courtesy of MAZDA MOTORS CORP.
  16. Disconnect the vacuum hose to the vacuum reservoir.
    Fig 7: Disconnecting Vacuum Hose To Vacuum Reservoir
    G03728209Courtesy of MAZDA MOTORS CORP.
  17. Disconnect the engine-to-degas bottle bypass hose.
    Fig 8: Disconnecting Engine-To-Degas Bottle Bypass Hose
    G03728210Courtesy of MAZDA MOTORS CORP.
  18. Disconnect the degas bottle-to-engine supply hose.
    Fig 9: Disconnecting Degas Bottle-To-Engine Supply Hose
    G03728211Courtesy of MAZDA MOTORS CORP.
  19. Disconnect the A/C compressor clutch.
    Fig 10: Disconnecting A/C Compressor Clutch
    G03728212Courtesy of MAZDA MOTORS CORP.
  20. Disconnect the mass airflow sensor (MAF) electrical connector.
    Fig 11: Disconnecting Mass Airflow Sensor (MAF) Electrical Connector
    G03728213Courtesy of MAZDA MOTORS CORP.
  21. Disconnect the A/C compressor manifold, plug the lines and the compressor ports.
    Fig 12: Disconnecting A/C Compressor Manifold - With Torque Specification
    G03728214Courtesy of MAZDA MOTORS CORP.
  22. Position the accelerator and cruise control cables aside.
    1. Disconnect the accelerator cable and cruise control cable (if so equipped) from the throttle linkage.
    2. Disconnect the accelerator cable and cruise control cable (if so equipped) from the mounting bracket and position out of the way.
      Fig 13: Disconnecting Accelerator And Cruise Control Cables
      G03728215Courtesy of MAZDA MOTORS CORP.
  23. Disconnect and position aside the following:
    1. The power steering pressure (PSP) switch electrical connector.
    2. The high pressure power steering hose.
    Fig 14: Disconnecting Power Steering Pressure Switch Electrical Connector & High Pressure Power Steering Hose
    G03728216Courtesy of MAZDA MOTORS CORP.
  24. Disconnect the fuel supply tube. See FUEL INJECTION SUPPLY MANIFOLD AND FUEL INJECTOR - 2.3L REMOVAL/INSTALLATION .
  25. Disconnect the following:
    • 42-pin electrical connector.
    • Evaporative purge hose.
      Fig 15: Disconnecting 42-Pin Electrical Connector And Evaporative Purge Hose
      G03728217Courtesy of MAZDA MOTORS CORP.
  26. Disconnect the brake booster vacuum hose and the engine ground strap.
    Fig 16: Disconnecting Brake Booster Vacuum Hose & Engine Ground Strap - With Torque Specification
    G03728218Courtesy of MAZDA MOTORS CORP.
  27. Disconnect the negative battery cable. Disconnect the positive battery cable. Disconnect the solenoid control wire at the starter.
    Fig 17: Disconnecting Negative And Positive Battery Cables - With Torque Specification
    G03728219Courtesy of MAZDA MOTORS CORP.
  28. Remove the starter wiring harness clamp bolt and position it out of the way.
    Fig 18: Removing Starter Wiring Harness Clamp Bolt - With Torque Specification
    G03728220Courtesy of MAZDA MOTORS CORP.
  29. Position the RH splash shield out of the way.
    Fig 19: Removing RH Splash Shield
    G03728221Courtesy of MAZDA MOTORS CORP.
  30. Disconnect the alternator electrical connections.
    31. Fig 20: Disconnecting Alternator Electrical Connections - With Torque Specification
    G03728222Courtesy of MAZDA MOTORS CORP.
  31. Detach alternator wiring pin-type retainer.
    Fig 21: Detaching Alternator Wiring Pin-Type Retainer
    G03728223Courtesy of MAZDA MOTORS CORP.
  32. Disconnect the block heater electrical connector, if equipped.
    Fig 22: Disconnecting Block Heater Electrical Connector
    G03728224Courtesy of MAZDA MOTORS CORP.
  33. Disconnect the front heated oxygen sensor (HO2S) electrical connector at the bell housing.
    Fig 23: Disconnecting Front Heated Oxygen Sensor (HO2S) Electrical Connector
    G03728225Courtesy of MAZDA MOTORS CORP.
  34. If the vehicle is equipped with an automatic transmission, remove the bolt retaining the transmission cooling tubes to the engine and remove the bracket.
    Fig 24: Removing Bracket Bolt - With Torque Specification
    G03728226Courtesy of MAZDA MOTORS CORP.
  35. Remove the transmission dust shield.
    Fig 25: Removing Transmission Dust Shield Bolts - With Torque Specification
    G03728227Courtesy of MAZDA MOTORS CORP.
  36. Remove the exhaust manifold-to-front pipe nuts.
    Fig 26: Removing Exhaust Manifold-To-Front Pipe Nuts - With Torque Specification
    G03728228Courtesy of MAZDA MOTORS CORP.
  37. Disconnect the rear heated oxygen sensor (HO2S) electrical connector near the rear of the transmission.
    Fig 27: Disconnecting Rear Heated Oxygen Sensor (HO2S) Electrical Connector
    G03728229Courtesy of MAZDA MOTORS CORP.
  38. Remove the engine wiring harness pin-type retainer.
    Fig 28: Removing Engine Wiring Harness Pin-Type Retainer
    G03728230Courtesy of MAZDA MOTORS CORP.
  39. Remove the engine wiring harness anchor and the pin-type retainer, then position the wiring harness aside.
    Fig 29: Removing Engine Wiring Harness Anchor & Pin-Type Retainer
    G03728231Courtesy of MAZDA MOTORS CORP.
  40. Disconnect the oil pressure sensor electrical connector.
    Fig 30: Disconnecting Oil Pressure Sensor Electrical Connector
    G03728232Courtesy of MAZDA MOTORS CORP.
  41. Remove the engine oil filter.
    Fig 31: Removing Engine Oil Filter
    G03728233Courtesy of MAZDA MOTORS CORP.
  42. If equipped with automatic transmission, disconnect the transmission wiring harness.
    • Disconnect the vehicle speed sensor, transmission range sensor, backup light switch and the transmission electrical connectors.
    • Disconnect the push-pins and position the harness forward to the engine.
      Fig 32: Disconnecting Transmission Wiring Harness
      G03728234Courtesy of MAZDA MOTORS CORP.
  43. If equipped with manual transmission, disconnect the electrical connector on the crossmember and the speed sensor electrical connector.
    Fig 33: Disconnecting Electrical Connector Of Crossmember And Speed Sensor Electrical Connector
    G03728235Courtesy of MAZDA MOTORS CORP.
  44. If equipped with manual transmission, disconnect the reverse lamp electrical connector and the two wiring pin-type retainers.
    Fig 34: Disconnecting Reverse Lamp Electrical Connector
    G03728236Courtesy of MAZDA MOTORS CORP.
    Fig 35: Removing Oil Filter Adapter Nuts - With Torque Specification
    G03728237Courtesy of MAZDA MOTORS CORP.
  45. Remove the oil filter adapter.
  46. Remove the starter motor. See STARTER MOTOR REMOVAL/INSTALLATION - 2.3L .
  47. Remove the starter dust shield.
    Fig 36: Removing Starter Dust Shield
    G03728238Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Mark one stud and the flexplate for assembly reference.
  48. If equipped with automatic transmission, remove the four torque converter nuts.
    NOTE:
    • Leave two side bolts in until the engine is ready to be removed.
    Fig 37: Removing Torque Converter Nuts - With Torque Specification
    G03728239Courtesy of MAZDA MOTORS CORP.
  49. Remove nine of the transmission-to-engine bolts.
    Fig 38: Removing Transmission-To-Engine Bolts - With Torque Specification
    G03728240Courtesy of MAZDA MOTORS CORP.
  50. On vehicles equipped with an automatic transmission, remove the transmission fluid indicator and tube assembly.
    Fig 39: Removing Transmission Fluid Indicator And Tube Assembly
    G03728241Courtesy of MAZDA MOTORS CORP.
  51. Install the Engine Lifting Bracket.
    Fig 40: Installing Engine Lifting Bracket
    G03728242Courtesy of MAZDA MOTORS CORP.
  52. Support the transmission with a floor jack.
  53. Support the engine with the Floor Crane using the Spreader Bar.
    Fig 41: Supporting Engine With Floor Crane Using Spreader Bar
    G03728243Courtesy of MAZDA MOTORS CORP.
  54. Remove the two side transmission-to-engine bolts.
    Fig 42: Removing Engine Support Insulator Nuts - With Torque Specification
    G03728244Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Left side shown, right side similar.
  55. Remove the four engine support insulator nuts.
  56. Remove the engine from the vehicle.
  57. On vehicles equipped with a manual transmissions, remove the clutch. See CLUTCH DISC AND COVER REMOVAL/INSTALLATION .
  58. Remove the flywheel or flexplate. See FLY-WHEEL/FLEXPLATE REMOVAL/INSTALLATION - 2.3L .
  59. Mount the engine on a suitable work stand.
  60. Install in the reverse order of removal.
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