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Engine Installation

WARNING:
  • When removing/installing the engine, verify that the engine and transaxle are securely supported. Otherwise, the engine may fall off and cause serious injury or death, and damage to the vehicle.
CAUTION:
  • Slots have been adopted for the No. 3 engine mount and No. 4 engine mount bracket installation holes. Tighten the installation bolts and nuts so that they are centered on the slots. Otherwise, engine noise or vibration could increase.
NOTE:
  • Retighten the engine front cover and transaxle stud bolts when the nuts of No. 3 engine mount and No. 4 engine mount bracket are loosened.
  1. Tighten the engine front cover stud bolts.
    Fig 1: Engine Front Cover Stud Bolts
    G09074286Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    7-13 N.m {72-132 kgf.cm, 62-115 in.lbf}

  2. Measure the projection of the transaxle stud bolts. (MTX)
    • If the projection amount is not within the range, adjust the projection amount of the stud bolt.
    Fig 2: Checking Projection Of Transaxle Stud Bolts (MTX) Measurements
    G11429840Courtesy of MAZDA MOTORS CORP.

    Projection A of stud bolt No. 1 

    40-42 mm {1.58-1.65 in}

    Projection B of stud bolt No. 2 

    30.7-32.7 mm {1.21-1.28 in}

    Projection C of stud bolt No. 3 

    70.7-72.7 mm {2.79-2.86 in}

  3. Tighten the transaxle stud bolts. (ATX)
    Fig 3: Transaxle And Stud Bolts
    G11429841Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    15-25 N.m {1.6-2.5 kgf.m, 12-18 ft.lbf}

    CAUTION:
    • When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent the deformation of the oil pan and damage of the transaxle.
  4. Secure the engine and transaxle using a commercially available engine lifter.
    Fig 4: Protecting Engine And Transaxle Using Engine Lifter
    G11429838Courtesy of MAZDA MOTORS CORP.
  5. Return the engine and transaxle to their original positions.
  6. Temporarily tighten the No. 3 engine mount installation bolts and nuts using the following procedure:
    1. Temporarily tighten the bolts so that the bolt holes of the body are centered on the No. 3 engine mount slots.
      Fig 5: Centering Bolt Holes Of Body On Engine Mount Slots (Good)
      G11429843Courtesy of MAZDA MOTORS CORP.
    2. Temporarily tighten the nuts so that the stud bolts of the engine front cover are centered on the No. 3 engine mount slots.
      • If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the engine, and temporarily tighten the installation nuts.
    Fig 6: Centering Stud Bolts Of Engine Front Cover On Engine Mount Slots
    G11429844Courtesy of MAZDA MOTORS CORP.
  7. Temporarily tighten the No. 4 engine mount bracket installation bolt and nuts using the following procedure:
    1. Temporarily tighten the bolt shown in the figure.

      MTX 

      Fig 7: Engine Mount Bracket And Installation Bolt (MTX)
      G11429845Courtesy of MAZDA MOTORS CORP.

      ATX 

      Fig 8: Engine Mount Bracket And Installation Bolt (ATX)
      G11429846Courtesy of MAZDA MOTORS CORP.
    2. Temporarily tighten the nuts so that the stud bolts of the transaxle are centered on the No. 4 engine mount bracket slots.
      • If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the transaxle, and temporarily tighten the installation nuts.

      MTX 

      Fig 9: Centering Stud Bolts Of Transaxle On Engine Mount Bracket Slots (MTX)
      G11429847Courtesy of MAZDA MOTORS CORP.

      ATX 

      Fig 10: Centering Stud Bolts Of Transaxle On Engine Mount Bracket Slots (ATX)
      G11429848Courtesy of MAZDA MOTORS CORP.
  8. Install the No. 1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION .)
    NOTE:
    • At this stage, only temporarily tighten the No. 1 engine mount rubber, do not tighten it completely.
  9. Tighten the No. 3 engine mount installation bolts and nuts in the order shown in the figure.
    Fig 11: Engine Mount Installation Bolts And Nuts Tightening Sequence
    G11429849Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    Installation position Tightening torque
    1 76-95 N.m {7.8-9.6 kgf.m, 57-70 ft.lbf}
    2 82-95 N.m {8.4-9.6 kgf.m, 61-70 ft.lbf}
    3 49-65 N.m {5.0-6.6 kgf.m, 37-47 ft.lbf}
  10. Tighten the No. 4 engine mount bracket installation bolt and nuts in the order shown in the figure.

    MTX 

    Fig 12: Engine Mount Bracket Installation Bolt And Nuts Tightening Sequence (MTX)
    G11429850Courtesy of MAZDA MOTORS CORP.

    ATX 

    Fig 13: Engine Mount Bracket Installation Bolt And Nuts Tightening Sequence (ATX)
    G11429851Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    Installation position Tightening torque
    1, 2, 3 92-116 N.m {9.4-11 kgf.m, 68-85 ft.lbf}
    4 81-99 N.m {8.3-10 kgf.m, 60-73 ft.lbf}
  11. Tighten the No. 1 engine mount rubber installation bolts.

    2WD 

    Fig 14: Engine Mount Rubber Installation Bolts Tightening Sequence (2WD)
    G11429852Courtesy of MAZDA MOTORS CORP.

    AWD 

    Fig 15: Engine Mount Rubber Installation Bolts Tightening Sequence (AWD)
    G11429853Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    Installation position Tightening torque
    1 141-172 N.m {15-17 kgf.m, 104-126 ft.lbf}
    2 130-164 N.m {14-16 kgf.m, 96-120 ft.lbf}
  12. Install the front drive shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION .)
  13. Install the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION .)
  14. Install the TWC to the exhaust manifold side) and secure the TWC using wire or rope so that it is out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  15. Install the A/C compressor. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5] .)
  16. Install the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  17. Connect the lower radiator hose. (See THERMOSTAT REMOVAL/INSTALLATION .)
  18. Connect the upper radiator hose. (See COOLING FAN MOTOR REMOVAL/INSTALLATION .)
  19. Install the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION .)
  20. Connect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION .)
  21. Connect the evaporative hose. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION .)
  22. Connect the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION .)
  23. Connect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION .)
  24. Install the clutch release cylinder. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R] .)
  25. Connect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION .)
  26. Connect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R] .)
  27. Connect the ground cable shown in the figure.

    RH 

    Fig 16: Engine Mount, Bolts, Ground Cable And Clips (RH)
    G11429835Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    9-12 N.m {92-122 kgf.cm, 80-106 in.lbf}

    LH 

    Fig 17: Engine Mount Bracket, Bolt, Ground Cable (LH)
    G11429836Courtesy of MAZDA MOTORS CORP.

    Tightening torque 

    9-12 N.m {92-122 kgf.cm, 80-106 in.lbf}

  28. Install the battery tray and battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5] .)
  29. Install the PCM component. (See PCM REMOVAL/INSTALLATION .)
  30. Connect the wiring harness shown in the figure.
    Fig 18: Installing Wiring Harness With Nuts And Bolts With Torque Specifications
    G11429856Courtesy of MAZDA MOTORS CORP.
  31. Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  32. Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION .)
  33. Refill the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [FW6AX-EL] .)
  34. Refill the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R] .) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT .)
  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), transfer oil (AWD) 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.
  37. Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION .)
  38. Install 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 .)
  39. Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
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