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Engine Removal/Installation [MZI-3.7]: Notes

WARNING: This page is about a different car, the 2009 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION [MZI-3.7] .)
  1. Perform "Fuel Line Safety Procedures". Leave the fuel pump relay removed. (See BEFORE SERVICE PRECAUTION [MZI-3.7] .)
  2. Disconnect both battery cables
  3. Remove the battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZI-3.7] .)
  4. Drain the power steering fluid (See POWER STEERING FLUID INSPECTION .)
  5. Drain the engine coolant (See ENGINE COOLANT REPLACEMENT [MZI-3.7] .)
  6. Drain the ATF (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL] .)
  7. Remove the engine cover (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7] .)
  8. Disconnect the purge hose from the dynamic chamber side
  9. Disconnect the vacuum hose (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
  10. Remove the air cleaner (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
  11. Remove the aerodynamic under cover No 1. (See AERODYNAMIC UNDER COVER NO. 1 REMOVAL/INSTALLATION .)
  12. Remove the both front wheels and tires (See GENERAL PROCEDURES (SUSPENSION) .)
  13. Remove the both front mudguards (See FRONT MUDGUARD REMOVAL/INSTALLATION .)
  14. Remove the both front splash shields
  15. Remove the generator and A/C drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7] .)
  16. Disconnect the front drive shaft (RH) from the joint shaft side (See DRIVE SHAFT REMOVAL/INSTALLATION .)
  17. Disconnect the front drive shaft (LH) from the transaxle side. (See DRIVE SHAFT REMOVAL/INSTALLATION .)
  18. Remove the front pipe (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7] .)
  19. Disconnect the shift cable from the transaxle side (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6A-EL] .)
  20. Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION .)
  21. Disconnect the power steering oil pump hose out of the way. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [MZI-3.7] .)
  22. Disconnect the power steering return hose. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [MZI-3.7] .)
  23. Disconnect the radiator hose from the engine side (See RADIATOR REMOVAL/INSTALLATION [MZI-3.7] .)
  24. Disconnect the water hose from the thermostat side
  25. Disconnect the ATF oil cooler hose.
  26. Disconnect the plastic fuel hose (See BEFORE SERVICE PRECAUTION [MZI-3.7] ) (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7] .)
  27. Disconnect the power steering reserve tank out of the way. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [MZI-3.7] .)
  28. Remove the wiring harness bolt and nuts shown in the figure.
    29. Fig 1: Wiring Harness Bolt & Nuts With Torque Specifications
    G06199351Courtesy of MAZDA MOTORS CORP.
  29. Disconnect the wiring harness.
    NOTE:
    • Do not disconnect the engine side of this wiring harness.
  30. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION .)
  31. Remove the engine and transaxle component using an engine jack in the order indicated in the figure.
  32. Install in the reverse order of removal.
  33. Start the engine and:
    1. Inspect the runout and contact on the pulley and belt.
    2. Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
    3. Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZI-3.7] .)
    4. Engine accessories operation.
  34. Perform a road test.
    NOTE:
    • If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no malfunction.
    Fig 2: Engine Mount Replacement Components With Torque Specifications
    G06199352Courtesy of MAZDA MOTORS CORP.
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