626 1999-2001

Engine

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Removal & Installation



2.0L (Fs) Engine

Specific to:

Mazda 626 1999-2002


NOTE
The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recommended.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Radiator
     
    Air cleaner assembly
     
    Accelerator cable
     
    Fuel hoses
     
    Front exhaust pipe
     
    Any rods, pipes or cables related to the transaxle that would hinder removal
     
    Battery
     
    Fuse box
     
    Power steering pump with the lines still attached and set aside
     
    A/C compressor with the lines still attached and position aside
     
    Cruise actuator connector, actuator retainers and the actuator
     
    Halfshafts
     
    Number 5 engine mount retainers. Refer to the accompanying illustration for location.
     
    Engine mount member (2) retainers. Refer to the accompanying illustration for location.
     
    Number 1 engine mount stay bracket retainers. Refer to the accompanying illustration for location.
     
    Number 3 engine mount rubber retainers. Refer to the accompanying illustration for location.
     
    Number 3 engine bracket retainers. Refer to the accompanying illustration for location.
     
    Number 1 engine mount nut and bolt. Refer to the accompanying illustration for location.
     
    Number 4 engine mount rubber retainers. Refer to the accompanying illustration for location.
     
    Number 4 engine bracket retainers. Refer to the accompanying illustration for location.
     
    Engine and transaxle assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications-626 models equipped with the 2.0L (FS) engine



    Click image to see an enlarged view

    Fig. Tighten the number 4 engine bracket retainers in the sequence shown-626 models equipped with the 2.0L (FS) engine

     

  12.  

To install:

  1. Installation is the reverse of removal. Tighten the fasteners to the specifications shown in the accompanying illustration.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmission assembly in the vehicle.
  4.  
  5. Install or connect the following:

    Number 4 engine bracket retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 4 engine mount rubber retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 1 engine mount nut and bolt. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 3 engine bracket retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 3 engine mount rubber retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 1 engine mount stay bracket retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Engine mount member (2) retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 5 engine mount retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     

  6.  
  7. When connecting the accelerator cable, perform the following adjustment:
    1. Move the white locking tab to the unlock position.
    2.  
    3. Turn stopper B to the to the unlock position.
      NOTE
      If stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

    4.  
    5. Push or pull the cable housing directly behind the spring.
    6.  
    7. Turn the stopper B to the lock position.
    8.  
    9. Measure the free play which should be 0.06-0.15 inch (1.5-4mm) and make sure the cable free play is within specification.
    10.  
    11. Move the white locking tab to the lock position and check for proper accelerator operation.

      Click image to see an enlarged view

      Fig. Accelerator cable adjustment components-626 models equipped with the 2.0L (FS) engine

    12.  

  8.  
  9. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  10.  
  11. Connect the negative battery cable, start the engine and check for leaks.
  12.  
  13. Check the ignition timing and the idle speed.
  14.  
  15. Check all fluid levels.
  16.  

2.5L (Kl) Engine

Specific to:

Mazda 626 1999-2002


NOTE
The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recommended.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Negative battery cable
     
    Radiator
     
    Air cleaner assembly
     
    Accelerator cable
     
    Fuel hoses
     
    Front exhaust pipe
     
    Any rods, pipes or cables related to the transaxle that would hinder removal
     
    Battery
     
    Power steering pump with the lines still attached and set aside
     
    A/C compressor with the lines still attached and position aside
     
    Cruise actuator connector, actuator retainers and the actuator
     
    Halfshafts
     
    Number 5 engine mount retainers. Refer to the accompanying illustration for location.
     
    Engine mount member (2) retainers. Refer to the accompanying illustration for location.
     
    Number 1 engine mount stay bracket retainers. Refer to the accompanying illustration for location.
     
    Number 3 engine mount rubber retainers. Refer to the accompanying illustration for location.
     
    Number 1 engine mount nut and bolt. Refer to the accompanying illustration for location.
     
    Number 4 engine mount rubber retainers. Refer to the accompanying illustration for location.
     
    Number 4 engine bracket retainers. Refer to the accompanying illustration for location.
     
    Engine and transaxle assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications-626 models equipped with the 2.5L (KL) engine

     

  12.  

To install:

  1. Installation is the reverse of removal. Tighten the fasteners to the specifications shown in the accompanying illustration.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmission assembly in the vehicle.
  4.  
  5. Install or connect the following:

    Number 4 engine bracket retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 4 engine mount rubber retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 1 engine mount nut and bolt. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 3 engine mount rubber retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 1 engine mount stay bracket retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Engine mount member (2) retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 5 engine mount retainers. Tighten the fasteners to the specifications shown in the accompanying illustration.
     

  6.  
  7. When connecting the accelerator cable, perform the following adjustment:
    1. Move the white locking tab to the unlock position.
    2.  
    3. Turn stopper B to the to the unlock position.
      NOTE
      If stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

    4.  
    5. Push or pull the cable housing directly behind the spring.
    6.  
    7. Turn the stopper B to the lock position.
    8.  
    9. Measure the free play which should be 0.06-0.15 inch (1.5-4mm) and make sure the cable free play is within specification.
    10.  
    11. Move the white locking tab to the lock position and check for proper accelerator operation.

      Click image to see an enlarged view

      Fig. Accelerator cable adjustment components-626 models equipped with the 2.5L (KL) engine

    12.  

  8.  
  9. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  10.  
  11. Connect the negative battery cable, start the engine and check for leaks.
  12.  
  13. Check the ignition timing and the idle speed.
  14.  
  15. Check all fluid levels.
  16.  

 
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