Mazda 323/626/929/GLC/MX-6/RX-7 1978-1989

Engine

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REMOVAL & INSTALLATION



Rear Wheel Drive GLC
EXCEPT WAGON
  1. Mark the outline of the hood hinges for reinstallation alignment. Unfasten the bolts and remove the hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system by opening the radiator drain cock.
  6.  
  7. Disconnect upper and lower water hoses.
  8.  
  9. Remove radiator.
  10.  
  11. Remove air cleaner.
  12.  
  13. Disconnect the ECS hoses, heater hose, accelerator and choke cables, fuel lines and vacuum hoses.
  14.  
  15. Disconnect the wiring from the distributor, starter, temperature sending unit, thermostatic switch, and alternator.
  16.  
  17. Disconnect the exhaust pipe at the exhaust manifold.
  18.  
  19. Remove the starter.
  20.  
  21. Safely support the car on axle stands and support the transmission with a jack.
  22.  
  23. Connect a suitable lifting sling to the engine hanger brackets and to a hoist, then take up the slack. Remove the engine mount bolts.
  24.  
  25. Remove transmission mounting bracket from the left side, and transmission-to-engine bolts from the right side.
  26.  
  27. Pull the engine forward until it clears the transmission input shaft, then remove it from the vehicle.
  28.  
  29. Installation is the reverse of the removal procedure.
  30.  

GLC WAGON
  1. Mark its location on the hinges, then unfasten the bolts and remove the hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Allow the engine to cool and drain the coolant.
  6.  
  7. Disconnect the upper and lower radiator hoses. On vehicles with automatic transmissions, disconnect the transmission cooler lines at the radiator, being careful to collect the transmission fluid that drains out.
  8.  
  9. Remove the radiator and cooling fan. Remove the air cleaner assembly (first disconnect the air hoses). Disconnect the accelerator cable. Cover the carburetor inlet to keep dirt out.
  10.  
  11. Disconnect the necessary wiring:

    Distributor primary leads
     
    Coil-to-distributor high tension wire
     
    Oil pressure gauge line
     
    Water temperature gauge line
     
    Accelerator switch wire
     
    Slow fuel cut solenoid wire
     
    Automatic choke wire
     
    Engine ground strap
     
    Starter motor wiring
     

  12.  
  13. Remove the right side engine mount through-bolt.
  14.  
  15. Disconnect the wire from the alternator B terminal and the alternator wiring connector.
  16.  
  17. Disconnect the air control valve and air vent hoses, all vacuum hoses, and the fuel lines.
  18.  
  19. Disconnect the accelerator cable, power brake vacuum hose, and heater hoses. Remove the hot air hose leading to the air cleaner.
  20.  
  21. Remove the left side engine mount through-bolt.
  22.  
  23. Raise the vehicle and safely support it on axle stands or a lift. Working underneath, disconnect the exhaust pipe and clutch cable. Remove the clutch cable bracket, and the lower clutch cover.
  24.  
  25. Support the transmission securely from underneath. On automatic transmission equipped vehicles, remove the bolts fastening the torque converter to the drive plate. Then, remove the transmission support bolts and nuts (automatic or manual transmission).
  26.  
  27. Remove the starter motor. Remove the forward catalytic converter.
  28.  
  29. Attach a lifting sling to the engine lifting brackets, and support the engine with the sling and a hoist. Slide the engine forward until it clears the clutch shaft (manual transmission) or torque converter (automatic transmission), and lift it out of the vehicle.
  30.  
  31. Install the engine in reverse order, torquing the clutch cover to 13-20 ft. lbs. (18-27 Nm), or the drive plate-to-torque converter bolts to 25-36 ft. lbs. (34-49 Nm) and converter housing-to-engine bolts to 23-34 ft. lbs. (31-46 Nm).
  32.  

Front Wheel Drive GLC

See Figures 1 and 2

The manufacturer recommends that the engine and transaxle be removed from the car as a unit.

  1. Mark the outline of the hood hinges for reinstallation alignment. Unfasten the bolts and remove the hood.
  2.  
  3. Disconnect the battery cables from the battery, negative cable first. Remove the battery.
  4.  
  5. Loosen the front wheel lugs. Jack up the car and safely support it on jackstands.
  6.  
  7. Remove the two front wheels. Remove the bottom and side splash shields.
  8.  



Click image to see an enlarged view

Fig. Fig. 1: Engine mount through-bolt-1981-82 front wheel drive GLC



Click image to see an enlarged view

Fig. Fig. 2: Engine mount through-bolt-1983-85 front wheel drive GLC

  1. Drain the coolant, engine oil and transaxle fluid.
  2.  
  3. Remove the air cleaner assembly. Remove the radiator hoses and the radiator shroud and electric fan assembly.
  4.  
  5. Connect an engine lifting sling to the engine lifting brackets. Connect a chain hoist or portable engine crane to the lifting sling, then apply slight upward pressure to the engine and transaxle assembly.
  6.  
  7. Remove the mounting bolts from the engine crossmember. Remove the crossmember.
  8.  
  9. Disconnect the lower ball joints, the steering knuckles and drive axles. For details, please refer to Suspension & Steering .
  10.  
  11. For cars equipped with a manual transaxle, disconnect the shifting rod and extension bar.
  12.  
  13. For cars equipped with an automatic transaxle, disconnect the selector rod and counter rod.
  14.  
  15. Remove the front and rear transaxle mounting bushings. Disconnect the exhaust pipe from the converter. Remove the transaxle crossmember.
  16.  
  17. Label, then disconnect all wires and hoses below the engine and transaxle.
  18.  
  19. Label, then disconnect all wires, heater hoses and vacuum hoses from the upper side of the engine and transaxle.
  20.  
  21. Disconnect the accelerator cable, speedometer cable, clutch cable, power brake booster line and fuel lines.
  22.  
  23. Check to be sure all remaining hoses and wiring are disconnected. Remove the evaporative canister. Remove the right side upper engine mount through-bolt.
  24.  
  25. Lift the engine/transaxle assembly from the car. Take care not to allow the assembly to swing forward into the radiator.
  26.  
  27. If the car must be moved from underneath the engine, remount the steering knuckles, secure the drive axles so that they can still turn, mount the front wheels and lower the car from the jackstands.
  28.  
  29. Installation is in the reverse order of removal. When installing the battery, connect the positive cable first.
  30.  

323-Except 1988-89 Turbo

On 1987 vehicles and on all 1988-89 vehicles equipped with fuel injection, release the pressure from the fuel system before beginning the engine removal procedure.

  1. Scribe matchmarks on the hood where the hinges attach, then unfasten the bolts and remove the hood.
  2.  
  3. Disconnect both battery cables, negative first. Remove the battery and the battery carrier.
  4.  
  5. Drain the engine oil, transaxle fluid and coolant.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the oil level dipstick and tube. Remove the cooling fan and the radiator assembly.
  10.  
  11. Remove the accelerator cable and, if so equipped, the cruise control cable. Disconnect the speedometer cable.
  12.  
  13. Disconnect the fuel hoses, draining them into a suitable container.
  14.  
  15. Disconnect and remove the heater hoses and the brake vacuum hose.
  16.  
  17. Disconnect and remove the three-way solenoid valve hoses and canister hoses.
  18.  
  19. Disconnect the engine harness connectors. Disconnect the engine ground strap.
  20.  
  21. Disconnect and remove the upper and lower radiator hoses. On vehicles with automatic transmissions, remove the secondary air pipe from the exhaust manifold.
  22.  
  23. Disconnect and lower the exhaust pipe, supporting it in a safe manner.
  24.  
  25. Unbolt and dismount the air conditioner compressor without attempting to disconnect the lines. Tie the compressor in a convenient spot so that the refrigerant lines will not be under tension.
  26.  
  27. Unbolt and dismount the power steering pump without attempting to disconnect the lines. Tie the pump in a convenient spot so that the lines will not be under tension.
  28.  
  29. Disconnect the driveshafts at the transaxle on either side, as described in Drive Train .
  30.  
  31. Disconnect and remove the clutch control cable and shift control rod on manual transmission cars, or the shift control cable on automatic transmission cars.
  32.  
  33. Remove the splash shields from under the engine and on both sides.
  34.  
  35. Unbolt the engine mounts at the body and remove them. Attach a lifting sling to the engine's lifting brackets and, using a hoist, remove the engine/transaxle assembly from above.
  36.  

To install:
  1. Carefully align the engine/transaxle assembly with its original position in the engine compartment. Then, work it slowly into position so as to avoid damaging anything. Install each item below in reverse order of the removal procedure.
    1. Engine mount-to-body bolts (see illustration for torque specifications).
    2.  
    3. Splash shields.
    4.  
    5. Shift control rod and clutch cable (manual transmission) or automatic transmission shift control cable.
    6.  
    7. Driveshafts (see Drive Train ).
    8.  
    9. Power steering pump (avoiding putting stress on the lines).
    10.  
    11. Air Conditioner compressor (avoiding putting stress on the lines).
    12.  
    13. Exhaust pipe and, on cars with automatic transmissions, the secondary air lines.
    14.  
    15. Upper and lower radiator hoses.
    16.  
    17. Engine ground strap.
    18.  
    19. Engine electrical connectors.
    20.  
    21. Emission canister hoses.
    22.  
    23. Three-way solenoid valve hoses.
    24.  
    25. Brake vacuum hose.
    26.  
    27. Heater hoses.
    28.  
    29. Fuel hoses.
    30.  
    31. Speedometer cable.
    32.  
    33. Accelerator and cruise control cable (if applicable).
    34.  
    35. Cooling fan and radiator (connect the hoses and electrical connectors).
    36.  
    37. Oil dipstick tube and dipstick.
    38.  
    39. Air cleaner assembly.
    40.  
    41. Battery tray and battery (positive cable first).
    42.  
    43. Hood, aligning the hinges as they were, using the matchmarks.
    44.  

  2.  
  3. Check all fluid levels and replenish as necessary, using approved antifreeze/water mixture, power steering fluid, and engine oil.
  4.  

1988-89 323 Turbo
  1. Release the pressure from the fuel system as described in Fuel System .
  2.  
  3. Scribe matchmarks on the hood where the hinges align, then unfasten the bolts and remove the hood.
  4.  
  5. Disconnect both battery cables, negative first.
  6.  
  7. Raise the front of the vehicle, support it safely with jackstands and block the rear wheels. Remove the front wheels.
  8.  
  9. Drain the engine oil, transaxle fluid and coolant into suitable containers.
  10.  
  11. Remove the battery and the battery carrier. Remove the air cleaner assembly.
  12.  
  13. If equipped, loosen the air conditioning unit from its mounting and slip the drive belt from the pulley. DO NOT disconnect the refrigerant hoses. Tie the unit off to the side of the vehicle or to the radiator support bracket, so that it will not interfere with the removal of the engine. Do the same for the power steering pump, if so equipped.
  14.  
  15. Remove the clutch release cylinder and disconnect the body-to-transmission ground cable and the back-up light switch connector.
  16.  
  17. Unfasten the engine harness connectors. Disconnect the shift control and speedometer cables from their respective linkages.
  18.  
  19. Loosen the hose clamps and remove the two heater hoses.
  20.  
  21. Disconnect the coolant temperature and cooling fan switch connectors.
  22.  
  23. Unbolt and remove the radiator.
  24.  
  25. Disconnect and remove the fuel and evaporator canister hoses. Plug the fuel hoses to prevent leakage and the entry of foreign matter. Have a small plastic container on hand to collect the excess fuel. Label and disconnect any vacuum hoses. Disconnect the accelerator cable from its linkage.
  26.  
  27. Loosen the hose clamps and remove the intercooler. Be careful not to damage the fins of the intercooler during removal. Cover the air pipe and hose openings with masking tape to prevent the entry of foreign matter.
  28.  
  29. Working from underneath the vehicle, unbolt and remove the side and under covers.
  30.  
  31. Label and disconnect the electrical leads and connectors from the starter, oil pressure switch and alternator.
  32.  
  33. Disconnect the driveshafts from either side. For details, please refer to Drive Train .
  34.  
  35. Unbolt and remove the exhaust pipe. On 4WD models, disconnect the propeller shaft (see Drive Train ). Remove the engine mount crossmember. Disengage the harness connector from the control unit and remove it. Store the control unit in a safe place.
  36.  
  37. Connect a lifting sling to the engine lifting brackets and attach a suitable hoist to the sling. Tension the hoist. Support the bottom of the transaxle with a jack.
  38.  
  39. Remove the No. 3 and No. 2 engine mounts (all models) and the No. 4 mount (4WD models only).
  40.  
  41. Lift the engine/transaxle assembly from the car and mount it on a stand or suitable holding fixture.
  42.  

To install:
  1. Carefully align the engine/transaxle assembly with its original position in the engine compartment. Then, work it slowly into position so as to avoid damaging anything. Install each item below in reverse order of the removal procedure:
    1. No. 3, No. 2 and No. 4 (4WD models only) engine-to-body mounts.
    2.  
    3. Control unit and harness connector.
    4.  
    5. Engine mount crossmember.
    6.  
    7. Propeller shaft (4WD models only).
    8.  
    9. Exhaust pipe and driveshafts.
    10.  
    11. Alternator, oil pressure switch and starter motor connectors.
    12.  
    13. Undercover and side covers.
    14.  
    15. Intercooler.
    16.  
    17. Accelerator cable, vacuum, canister and fuel hoses.
    18.  
    19. Radiator, cooling fan and thermoswitch connectors.
    20.  
    21. Speedometer and shift control cables, heater hoses and engine harness connectors.
    22.  
    23. Back-up light switch connector, body-to-transmission ground cable and clutch release cylinder.
    24.  
    25. Battery carrier, battery and cables (positive cable first).
    26.  
    27. Air cleaner assembly and front wheels.
    28.  
    29. Air conditioning compressor and power steering pump.
    30.  
    31. Hood, aligning the hinges as they were, using the matchmarks.
    32.  

  2.  
  3. Check all fluid levels and replenish as necessary, using approved antifreeze/water mixture, power steering fluid, and engine oil.
  4.  

1979-82 626
  1. Scribe matchmarks on the hood where the hinges align, then unfasten the bolts and remove the hood.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the upper and lower radiator hoses.
  8.  
  9. On cars equipped with an automatic transmission, disconnect the cooler lines at the radiator.
  10.  
  11. Remove the radiator cowling and fan.
  12.  
  13. Remove the radiator.
  14.  
  15. Remove the intake hoses from the air cleaner, then remove the air cleaner.
  16.  
  17. Disconnect the wiring from the distributor (primary), ignition coil, oil pressure gauge unit and the alternator B terminal. Disconnect the alternator wiring coupler, and remove the right side engine mounting nut.
  18.  
  19. Disconnect the wiring from the water temperature gauge unit, fuel cut solenoid, automatic choke, and starter motor.
  20.  
  21. Disconnect the air hoses (reed valve), vacuum hoses (three way solenoid valve), fuel hoses, acceleration wire, master vacuum hose, and the left side engine mounting nut.
  22.  
  23. Raise the front of the vehicle and safely support with jackstands.
  24.  
  25. Remove the under cover.
  26.  
  27. Disconnect the exhaust pipe.
  28.  
  29. Remove the clutch under cover plate and stays.
  30.  
  31. On cars equipped with automatic transmission, remove the torque converter and driving plate support bolts.
  32.  
  33. Support the transmission with a suitable jack, then remove the transmission supporting bolts and nuts.
  34.  
  35. Remove the starter motor and the clutch release cylinder.
  36.  
  37. Connect a suitable lifting sling to the engine hanger brackets and to a hoist, then remove the slack.
  38.  
  39. Pull the engine forward until it clears the clutch shaft, then lift the engine from the vehicle.
  40.  
  41. To install, reverse the removal procedure.
  42.  

1983-87 626
EXCEPT DIESEL

See Figures 3, 4 and 5

To perform this procedure, you will need a special tool, a differential side gear holder, Mazda part number 49 G030 455 or equivalent. For details, see the Driveshaft Removal and Installation procedure in Drive Train . You will also have to support the vehicle with the front wheels removed as you lift the engine from above.

  1. Scribe matchmarks on the hood where the hinges align, then unfasten the bolts and remove the hood.
  2.  
  3. On 1986-87 vehicles, release the fuel system pressure as described in Fuel System , before proceeding with the engine removal.
  4.  
  5. Disconnect both battery cables, negative first. Remove the air cleaner assembly.
  6.  
  7. Disconnect the fuel supply hose and, on 1983-85 models, the return hose. Disconnect the accelerator cable at the carburetor or injection system throttle body.
  8.  



Click image to see an enlarged view

Fig. Fig. 3: Tie the air conditioner compressor as shown while removing the engine-1983-87 626



Click image to see an enlarged view

Fig. Fig. 4: Remove the rubber cap (1) from the right wheelhouse and the bolt (2) shown in the illustration. Then, unfasten the arrowed bolts from inside the engine compartment and remove the torque stopper (3)-1983-87 626



Click image to see an enlarged view

Fig. Fig. 5: Remove the engine mount bolts from the locations shown-1983-87 626

  1. Disconnect the clutch cable (1983-85 models) or remove the clutch slave (release) cylinder (1986-87 models) from the transaxle. On automatic transaxle equipped models, disconnect the control cable.
  2.  
  3. Disconnect the engine ground strap. On 1986 models, disconnect the related connector at the same time. Disconnect the power brake unit vacuum hose. Remove the three-way valve vacuum switch and its mounting bracket from the firewall.
  4.  
  5. Drain the cooling system through both the radiator drain cock and the block drain plug. Then, disconnect and remove both heater hoses.
  6.  
  7. On 1983-85 models, disconnect the duty solenoid valve and vacuum sensor.
  8.  
  9. On all models, label and then disconnect all wiring to the engine and transaxle.
  10.  
  11. Disconnect both the air vent and vacuum hoses from the storage canister.
  12.  
  13. Remove the electric fan and radiator (refer to the procedures later in this section).
  14.  
  15. On air conditioned models, remove the windshield washer tanks and the alternator. (Refer to the alternator removal procedure earlier in this section.) For non-air conditioned models, proceed to Step 14.
  16.  
  17. On air conditioned models, remove the A/C compressor from its mounts without attempting to disconnect any refrigeration lines. Securely tie the compressor to the front cowl in such a way that the refrigerant lines are not under stress.
  18.  
  19. Raise the car and support it safely on jackstands. Remove the front wheels and splash shields.
  20.  
  21. On cars with manual steering, go on to Step 16. On cars with power steering, loosen the power steering pump pulley bolt. Then, remove the pump drive belt. Remove the power steering pump pulley and pump installation bolts, holding the pump so the hoses will not be stressed. Support the pump above the crossmember so that the hoses can remain connected without any stress.
  22.  
  23. Remove the driveshafts as described in Drive Train . Make sure to use a holder to prevent misalignment of the differential side gear splines and to keep the gears in position.
  24.  
  25. On cars with a manual transaxle, remove the shift rod and torque rod along with the related joints and nuts. Then, install a lifting sling and support the engine securely by the lifting brackets.
  26.  
  27. Remove the rubber cap from the right wheelhouse, and the bolt shown in the illustration. Remove the arrowed bolts from inside the engine compartment, then remove the torque stopper.
  28.  
  29. Disconnect the exhaust pipe.
  30.  
  31. Remove the mounting bolts (arrowed in the illustration) from the engine mounts. Then, carefully lift the engine/transaxle assembly out of the engine compartment. Take extra care not to damage air conditioner or power steering parts.
  32.  

To install:
  1. Carefully align the engine/transaxle assembly with its original position in the engine compartment. Then, work it slowly into position so as to avoid damaging anything.
  2.  
  3. Connect the exhaust pipe. Install the torque rods and bolts, and then the cap. Install the engine mount bolts.
  4.  
  5. Install each of the following items in the reverse order of removal:
    1. Shift rod and torque rod and related parts.
    2.  
    3. Driveshafts (refer to Drive Train ).
    4.  
    5. Power steering pump.
    6.  
    7. Splash shields and front wheels.
    8.  

  6.  
  7. Lower the car. Then, continue installing parts as listed:.
    1. Air conditioner compressor.
    2.  
    3. Alternator (if applicable).
    4.  
    5. Electric fan and radiator.
    6.  
    7. Air vent and vacuum hoses.
    8.  
    9. Wiring.
    10.  
    11. Heater hoses.
    12.  
    13. Three-way valve vacuum switch and bracket and the power brake unit vacuum hoses (make sure connections are secure).
    14.  
    15. Engine ground strap and connector.
    16.  
    17. Clutch release cylinder/cable or automatic transaxle control cable.
    18.  
    19. Speedometer and accelerator cables.
    20.  
    21. Fuel hose(s) and the air cleaner.
    22.  
    23. Battery cables (positive cable first).
    24.  
    25. Hood, aligning the hinges as they were, using the matchmarks.
    26.  

  8.  
  9. Check all fluid levels and replenish as necessary, using approved antifreeze/water mixture, power steering fluid, and engine oil.
  10.  

626 DIESEL

See Figures 4, 5 and 6

To perform this procedure, you will need a differential side gear holder, Mazda part number 49 G030 455 or equivalent. For details, see the Driveshaft Removal and Installation procedure in Drive Train . You will also have to support the vehicle with the front wheels off as you remove the engine from above.

  1. Scribe matchmarks on the hood where the hinges align, then unfasten the bolts and remove the hood.
  2.  
  3. Disconnect both battery cables, negative first.
  4.  
  5. Remove the oil filler and radiator caps. Then raise the vehicle and safely support the front end on jackstands.
  6.  



Click image to see an enlarged view

Fig. Fig. 6: Disconnect the fuel supply and return hoses, as well as the indicated electrical connectors

  1. Drain the engine oil and coolant. Drain the transaxle fluid. Remove both front wheels.
  2.  
  3. Disconnect the starter motor cable and ignition switch wire at the starter. Disconnect the oil pressure switch connection nearby.
  4.  
  5. Disconnect the lower radiator hose from the water inlet pipe on the block.
  6.  
  7. Disconnect the two rubber hoops which support the exhaust pipe at the crossmember. Then, unbolt the exhaust pipe at its support bracket and at the flange adjacent to the exhaust manifold.
  8.  
  9. Disconnect the shift control rod and torque rod at the transaxle.
  10.  
  11. Remove the tie rod clinch bolts and nuts, and then pry the lower control arms on both sides downward to separate the knuckle and lower ball joint.
  12.  
  13. Pry the right driveshaft out of the transaxle. See Drive Train of this repair guide.
  14.  
  15. Remove the engine mount attaching nuts. Then, lower the vehicle to the ground.
  16.  
  17. Remove the Quick Start and Afterglow relays from the air cleaner bracket. Then, unbolt and remove the air cleaner assembly and bracket.
  18.  
  19. Unbolt and remove the clutch release (slave) cylinder from the transaxle housing. Disconnect the speedometer cable from the transaxle housing, as well.
  20.  
  21. Remove the engine wiring harness bracket. Disconnect the ground strap or cable from the transaxle case. Disconnect the speedometer cable at the case, as well.
  22.  
  23. Disconnect the left side driveshaft from the transaxle (see Drive Train ). Make sure to install the required holder to prevent misalignment of the differential side gear splines and to keep the gears in position.
  24.  
  25. Disconnect the electric fan motor and back-up lamp switch connectors.
  26.  
  27. Disconnect the fuel supply and return hoses at the injection pump, draining the fuel into a suitable container. Cap the open ends to keep the connections clean.
  28.  
  29. Unfasten the glow plug connector, tachometer sensor connector and engine stop valve connector.
  30.  
  31. Unfasten the water temperature sensor connector (at the thermostat housing)
  32.  
  33. Disconnect the upper radiator hose at the thermostat housing. Disconnect the water lever sensor connector, water temperature switch connector and ground wire. Disconnect the lower radiator hose, then remove the radiator and its rubber mounts.
  34.  
  35. Disconnect the accelerator cable at the injection pump. Disconnect the cold start device cable at the injection pump. Then, disconnect the plug and terminal type connector from the alternator.
  36.  
  37. Disconnect the power brake vacuum hose at the pipe leading from the vacuum pump. Disconnect the two coolant hoses and two oil hoses from the oil cooler, draining them into a convenient container to avoid spillage.
  38.  
  39. On cars with a manual transaxle, remove the shift rod and torque rod and related joints and nuts.
  40.  
  41. Remove the rubber cap from the right wheelhouse, and the bolt shown in the illustration. Remove the arrowed bolts from inside the engine compartment, then remove the torque stopper.
  42.  
  43. Install a lifting sling and support the engine securely by the two lifting brackets.
  44.  
  45. Disconnect the engine ground strap at the body.
  46.  
  47. Remove the mounting bolts (arrowed in the illustration) from the engine mounts. Then, carefully lift the engine and transaxle assembly out of the engine compartment. Take extra care not to damage air conditioner or power steering parts.
  48.  

To install:
  1. Carefully align the engine with its original position in the engine compartment. Then, work it slowly into position so as to avoid damaging anything.
  2.  
  3. Install the engine mount bolts.
  4.  
  5. Install/reconnect each of the items below in reverse of its removal:
    1. Engine torque stopper.
    2.  
    3. Oil cooler hoses and brake vacuum hose.
    4.  
    5. Alternator wiring.
    6.  
    7. Cold start and accelerator cables to the injection pump.
    8.  
    9. Radiator and mounts.
    10.  
    11. Radiator hoses and wiring.
    12.  
    13. Water temperature sensor connector, fuel cut valve connector, tachometer connector and glow plug wiring connector.
    14.  
    15. Fuel injection pump supply and return hoses.
    16.  
    17. Back-up light and electric fan connectors.
    18.  
    19. Left side driveshaft (as described in Drive Train ).
    20.  
    21. Speedometer cable and engine ground (at the transaxle housing).
    22.  
    23. Engine electrical harness bracket.
    24.  
    25. Clutch release hydraulic cylinder.
    26.  
    27. Quick start and afterglow relays onto the air cleaner bracket.
    28.  
    29. Air cleaner and air cleaner bracket.
    30.  
    31. Right side driveshaft (as described in Drive Train ).
    32.  
    33. Tie rod ends.
    34.  
    35. Exhaust pipe and rubber supports.
    36.  
    37. Oil pressure sending unit, radiator lower hose (at the inlet pipe on the block), and the starter wiring.
    38.  

  6.  
  7. Replenish all fluids, reinstall the wheels and lower the vehicle to the ground.
  8.  
  9. Install the filler caps and reconnect the battery (positive cable first).
  10.  
  11. Reinstall the hood, aligning the hinges as they were, using the matchmarks.
  12.  

1988-89 626/MX-6
  1. Release the pressure from the fuel system as described in Fuel System .
  2.  
  3. Drain the engine oil and the cooling system.
  4.  
  5. Scribe matchmarks on the hood where the hinges align, then unfasten the bolts and remove the hood.
  6.  
  7. Disconnect the battery cables, negative first, then remove the battery and battery carrier.
  8.  
  9. Remove the fuse box and air cleaner assembly.
  10.  
  11. Tag and disconnect the spark plug wires from the distributor cap. Disconnect the accelerator cable from the throttle body. On automatic transaxle equipped vehicles, disconnect the throttle cable.
  12.  
  13. Disconnect the fuel hoses from the fuel injector rail. Plug the fuel hose openings to prevent leakage.
  14.  
  15. Loosen the hose clamps and remove the two radiator hoses. On manual transaxle equipped vehicles, disconnect the transaxle fluid cooler lines from the bottom of the radiator. Plug the openings to prevent leakage.
  16.  
  17. Unfasten the connector from the bottom of the radiator.
  18.  
  19. On turbocharged engines, disconnect the turbocharger pipe and hose. Cover the opening of the turbocharger with masking tape to prevent anything from falling into the turbine casing.
  20.  
  21. Unfasten the water thermoswitch connector.
  22.  
  23. Disconnect the fuel injection harness and label all the individual connectors. Do the same for the engine harness.
  24.  
  25. Disconnect the vacuum hose and the three-way solenoid assembly. On turbocharged engines, disconnect the EGR solenoid assembly.
  26.  
  27. Disconnect the heater hoses and the evaporative canister hoses.
  28.  
  29. Remove the harness from the transaxle. Disconnect the speedometer cable and the clutch release cylinder (manual transaxle, with the pipe still connected ) or control cable (automatic transaxle).
  30.  
  31. Remove the drive belts. If equipped, disconnect the air conditioning compressor and bracket from its mounting, and securely tie the unit off to the side of the vehicle with the lines still connected.
  32.  
  33. Position the power steering pump and pulley in the same manner as the air conditioner.
  34.  
  35. Working from underneath the vehicle, remove the engine side covers.
  36.  
  37. Raise the vehicle and safely support with jackstands. Block the rear wheels, then remove the front wheels.
  38.  
  39. Remove the tie rod ends, stabilizer control rod and lower arm control bushing (see Suspension & Steering ).
  40.  
  41. Pry the driveshafts from the transaxle as described in Drive Train . Make sure to use a holder to prevent misalignment of the differential side gear splines and to keep the gears in position.
  42.  
  43. On cars with a manual transaxle, remove the change rod and shift bar, along with the related joints and nuts. Remove the exhaust pipe.
  44.  
  45. Install a lifting sling and support the engine securely by the lifting brackets. Remove the engine mounts.
  46.  
  47. Lift the engine/transaxle from the engine and position the assembly on a stand or suitable holding fixture. Separate the transaxle from the engine.
  48.  

To install:
  1. Attach the transaxle to the engine.
  2.  
  3. Carefully line the engine up with its original position in the engine compartment. Then, work it slowly into position so as to avoid damaging anything.
  4.  
  5. Install the engine mount bolts.
  6.  
  7. Install each of the items below in reverse order of removal:
    1. Exhaust pipe. Torque the converter nuts to 47-66 ft. lbs. (64-89 Nm), manifold nuts to 23-34 ft. lbs. (31-46 Nm) and bracket bolt to 14-19 ft. lbs. (19-26 Nm).
    2.  
    3. Extension bar and change rod (manual transmissions). Torque the bar-to-transaxle bolt to 23-34 ft. lbs. (31-46 Nm).
    4.  
    5. Driveshafts. Grease the driveshaft splines and use new retaining clips. After installation, pull out on the drive hub to verify that the driveshaft is held properly by the clip.
    6.  
    7. Lower arm. Torque the locknut to 32-40 ft. lbs. (43-54 Nm).
    8.  
    9. Stabilizer control rod. Adjust the front stabilizer control rods so that there is 0.79 in. (20mm) from the top of the rod bolt to the bottom of the adjusting locknut. Once this dimension is obtained, torque the locknut to 12-17 ft. lbs. (16-23 Nm).
    10.  
    11. Tie rod ends. Connect the tie rod end to the steering knuckle and torque the castellated nut to 22-33 ft. lbs. (30-45 Nm). Install a new cotter pin and spread the ends.
    12.  
    13. Front wheels
    14.  

  8.  
  9. Lower the vehicle and install the following:
    1. Engine side covers.
    2.  
    3. Power steering pump and air conditioning compressor with pulleys and brackets. Torque the power steering pump mounting bolts to 23-34 ft. lbs. (31-46 Nm) and the pulley locknut to 29-43 ft. lbs. (39-58 Nm). Connect the air conditioning compressor strap to the power steering pump and torque the mounting bolt to 14-19 ft. lbs. (19-26 Nm). Torque the air conditioning compressor mounting bracket bolts to 27-46 ft. lbs. (37-62 Nm) and the mounting bolts with locknuts to 27-38 ft. lbs. (37-51 Nm).
    4.  
    5. Drive belts (adjust the deflection).
    6.  
    7. Control cable (on vehicles with an automatic transaxle). Adjust the shift selector position (see Drive Train ).
    8.  
    9. Clutch release cylinder (on vehicles with a manual transaxle). Torque the pipe bracket mounting bolts to 69-95 inch lbs. (8-11 Nm) and the cylinder mounting bolts to 14-19 ft. lbs. (19-26 Nm).
    10.  
    11. Speedometer cable.
    12.  
    13. Transaxle harness.
    14.  
    15. Heater and canister hoses.
    16.  
    17. EGR solenoid assembly (turbo). Torque the mounting nuts to 69-95 inch lbs. (8-11 Nm).
    18.  
    19. Three-way solenoid assembly. Torque the mounting nuts to 69-95 inch lbs. (8-11 Nm).
    20.  
    21. Brake vacuum hose.
    22.  
    23. Engine and fuel injection harnesses.
    24.  
    25. Water thermoswitch and heat gauge connectors.
    26.  
    27. Turbocharger pipe and hose (turbo). Torque the outer mounting nut to 47-66 ft. lbs. (64-89 Nm) and the inner mounting nut to 69-95 inch lbs. (8-11 Nm).
    28.  
    29. Radiator and cooling fan. Torque the mounting bolts to 69-95 inch lbs. (8-11 Nm).
    30.  
    31. Radiator harness.
    32.  
    33. Transaxle fluid hoses to radiator (automatic transaxle).
    34.  
    35. Fuel hoses.
    36.  
    37. Throttle cable (automatic transaxle).
    38.  
    39. Accelerator cable.
    40.  
    41. Spark plug wires.
    42.  
    43. Air cleaner assembly.
    44.  
    45. Battery tray, fuse box and battery (positive cable first).
    46.  
    47. Hood, aligning the hinges as they were, using the matchmarks.
    48.  

  10.  
  11. Check all fluid levels and replenish as necessary, using approved antifreeze/water mixture, power steering fluid, and engine oil. Adjust all drive belts, cables and linkages. Adjust the ignition timing and idle speed, as described in Engine Electrical .
  12.  

929
  1. Relieve the fuel system pressure as described in Fuel System .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine oil and the cooling system.
  6.  
  7. Scribe matchmarks on the hood where the hinges align, then unfasten the bolts and remove the hood.
  8.  
  9. Disconnect and remove the fresh air duct and the air cleaner assembly.
  10.  
  11. Disconnect the accelerator cable from the throttle body.
  12.  
  13. Remove the cooling fan pulley bolts, then remove the cooling fan and the radiator cowling.
  14.  
  15. Remove the drive belts, spark plug wires and spark plugs.
  16.  
  17. Disconnect the evaporative canister and brake hoses.
  18.  
  19. Disconnect the fuel hoses from the connections on the fuel rail ends. Plug the hoses to prevent leakage and the entry of foreign matter.
  20.  
  21. Remove the heater hoses and disconnect the engine wiring harness.
  22.  
  23. Working from underneath the vehicle, remove the engine undercover.
  24.  
  25. Loosen the hose clamps, then remove the upper and lower radiator hoses.
  26.  
  27. On models equipped with an automatic transmission, disconnect the automatic transmission fluid cooler lines from the radiator bottom. Plug the openings to prevent leakage.
  28.  
  29. Disconnect the radiator harness and remove the radiator.
  30.  
  31. Unbolt and remove the alternator and the alternator strap.
  32.  
  33. If equipped, disconnect the air conditioning compressor and bracket from its mounting and tie the unit off to the side of the vehicle with its lines intact and connected. Position the power steering pump in the same manner as the air conditioner.
  34.  
  35. Unbolt and remove the section of exhaust pipe that runs from the catalytic converter to the exhaust manifold.
  36.  
  37. Connect a lifting strap to the engine lifting brackets, then attach a hoist to the sling and tension the hoist. Support and remove the transmission. See Drive Train .
  38.  
  39. Remove the engine mounting nuts and lift the engine out of the vehicle.
  40.  
  41. Mount the engine on a stand or suitable holding fixture.
  42.  

To install:
  1. Position the engine into the vehicle. Using the hoist, guide the engine over the mount studs and install the engine mount nuts. Torque the mount nuts to 35-36 ft. lbs. (47-49 Nm).
  2.  
  3. Install the transmission by reversing the removal procedure.
  4.  
  5. Connect the exhaust pipe to the manifold and the converter. Torque the exhaust pipe nuts to 23-34 ft. lbs. (31-46 Nm).
  6.  
  7. Position and install the power steering pump onto its mounting. Torque the mounting bolts to 23-34 ft. lbs. (31-46 Nm).
  8.  
  9. Install the air conditioning compressor and torque the mounting bolts to 22-29 ft. lbs. (30-39 Nm).
  10.  
  11. Install the alternator and mounting strap. Torque the alternator mounting bolts to 27-38 ft. lbs. (37-51 Nm).
  12.  
  13. Install the radiator and torque the mounting bolts to 16-22 ft. lbs. (22-30 Nm). Connect the radiator harness and, if equipped with an automatic transmission, install the transmission fluid lines.
  14.  
  15. Connect the upper and lower radiator hoses. Make sure the clamps are positioned properly on the hose.
  16.  
  17. Connect heater, fuel, brake vacuum and evaporative canister hoses.
  18.  
  19. Coat the spark plug threads with a suitable anti-seize compound and torque the plugs to 11-17 ft. lbs. (15-23 Nm).
  20.  
  21. Install the cooling fan, alternator, power steering pump (if equipped), crankshaft pulley and air conditioning compressor drive belts. Adjust the drive belt tensions.
  22.  
  23. Install the radiator fan with the cowling. Install the cooling fan/pulley bolts and torque to 69-95 inch lbs. (8-11 Nm). Also torque the cowling bolts to 69-95 inch lbs. (8-11 Nm).
  24.  
  25. Working from underneath the vehicle, install the engine under cover and torque the mounting screws to 69-95 inch lbs. (8-11 Nm).
  26.  
  27. Connect the spark plug wires and the negative battery cable.
  28.  
  29. Connect the accelerator cable and check the cable deflection by pressing lightly on the cable. Cable deflection should be 0.04-0.12 in. (1-3mm).
  30.  
  31. Install the air cleaner assembly and the fresh air duct.
  32.  
  33. Replenish the engine and cooling system fluid levels, using approved antifreeze/water mixture, power steering fluid, and engine oil. Adjust all drive belts, cables and linkages. Set the ignition timing and idle speed, as described in Engine Electrical .
  34.  

 
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