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Engine Removal/Installation: Notes

WARNING: This page is about a different car, the 2004 Mazda RX-8. 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 from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" when servicing the fuel system. (See BEFORE REPAIR PROCEDURE .)
  • After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction. (See EPS SYSTEM NEUTRAL POSITION SETTING .)
CAUTION:
  • To allow the PCM to identify that the engine has been replaced, pump the brake pedal 20 times within 8 seconds after the ignition switch is turn to the ON position (engine off).
NOTE:
  • Remove the engine, transmission, and crossmember component as a single unit from under the vehicle.
  1. Remove the following parts:
    1. The front wheel and tires (See WHEEL AND TIRE INSTALLATION
    2. The engine cover (See ENGINE COVER REMOVAL/INSTALLATION .)
    3. The front suspension tower bar (See FRONT SUSPENSION TOWER BAR .)
    4. The battery cover, battery, battery box and battery tray.
    5. The air cleaner, intake-air duct and air cleaner insulator (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
    6. The PCM.
    7. The AIR pump. (See SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION
  2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  3. Disconnect the brake vacuum hose.
  4. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  5. Disconnect the plastic fuel hose. (See BEFORE REPAIR PROCEDURE .) (See FUEL INJECTOR REMOVAL/INSTALLATION .)
  6. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION .)
  7. Remove the A/C belt. (See DRIVE BELT REPLACEMENT .)
  8. 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.
  9. Disconnect the engine wiring harness from the main fuse block side.
  10. Remove the engine under cover.
  11. Disconnect front ABS wheel speed sensor connector. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION .)
  12. Disconnect the radiator hose, the heater hose and coolant reserve tank hose.
  13. A/T

    M/T

  14. Remove the engine, transmission, and crossmember component using an engine lifter in the order indicated. See Fig 1.
    WARNING:
    • Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
    Fig 1: Removing/Installing Engine
    G01345645Courtesy of MAZDA MOTORS CORP.
  15. Remove the engine and transmission from the crossmember component lifter in the order indicated by suspending them with a crane. See Fig 2.
    Fig 2: Removing Engine & Transmission
    G01345646Courtesy of MAZDA MOTORS CORP.
  16. Install in the reverse order of removal.
  17. Start the engine and inspect and adjust the following:
    • Pulley and belt for runout, tension, and contact.
    • Leakage of engine oil, engine coolant, ATF, M/T oil, and fuel.
    • Ignition timing, idle speed, and idle mixture (CO and HC). See ENGINE TUNE-UP .
    • Front wheel alignment. (See  WHEEL ALIGNMENT  .) 
    • Engine-driven accessories operation.
  18. Perform the on-road test and verify that there is no vibration or noise.
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