Mazda Car 2002-04

Engine 1

Print

Removal & Installation




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 in the beginning of this 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:

    Battery cables and battery
     
    Battery tray

    Click image to see an enlarged view

    Fig. View of typically removed external components for engine removal-front wheel drive models



    Click image to see an enlarged view

    Fig. View of the common electrical harness plug connector points-front wheel drive models

     
    Hood
     
    Front wheels
     
    Splash shield(s) from under the vehicle
     
    Air cleaner assembly and resonance chamber, including the air flow meter and all of the ducting
     
    Oil dipstick
     

  12.  
  13. On the Millenia with the 2.3L engine, remove the charge air cooler, front grille, upper seal board (panels that the grille mounts to) and coolant overflow tank.
  14.  
  15. Remove or disconnect the following:

    Radiator hoses
     
    Transmission oil cooler lines from the radiator, if equipped with automatic transaxle
     
    Cooling fan and radiator switch electrical connectors
     
    Radiator/cooling fan assembly
     
    Throttle and speedometer cables

    Click image to see an enlarged view

    Fig. Typical vacuum, fuel and water hose disconnect points for engine removal-front wheel drive models

     
    All vacuum hoses and wiring harnesses
     
    Fuel supply and return hoses
     
    Heater hoses
     
    Exhaust pipe from the manifold
     
    Accessory drive belt(s)
     
    Power steering pump and move it aside without disconnecting the hydraulic hoses
     
    A/C compressor and move it aside without disconnecting the lines
     
    Clutch cable and shift control rod, if equipped with manual transaxle
     
    Slave cylinder from the transaxle without disconnecting the hydraulic line, if equipped with hydraulic clutch

    Click image to see an enlarged view

    Fig. Typically removed 4-cylinder engine under-vehicle components for engine removal-front wheel drive models



    Click image to see an enlarged view

    Fig. Typically removed 6-cylinder engine under-vehicle components for engine removal-front wheel drive models

     
    Shift control cable, if equipped with automatic transaxle
     
    Tie rod ends from the steering knuckles
     
    Stabilizer bar from the lower control arms
     

  16.  
  17. Attach an engine lifting chain to the engine lifting eyes. Attach the chain to a suitable engine hoist and raise the hoist until there is tension on the chain.
  18.  
  19. Remove or disconnect the following:

    Engine mount member
     
    Lower ball joint from the steering knuckle
     
    Bolts from the right side intermediate shaft support, if equipped
     
    Intermediate shaft by prying it from the transaxle
     

  20.  
  21. Suspend the halfshafts with wire.
  22.  
  23. Remove or disconnect the following:

    Dynamic damper from the right side engine mount, if equipped.
     
    Engine/transaxle mount nuts/bolts and right engine (if equipped) and left transaxle mounts
     

  24.  
  25. Lift the engine/transaxle assembly from the vehicle.
  26.  
  27. Remove or disconnect the following:

    Intake manifold bracket
     
    Starter
     
    Torque converter nuts
     
    Engine-to-transaxle stiffener, if equipped
     
    No. 2 engine mount
     
    Throttle valve cable

    Click image to see an enlarged view

    Fig. Once all components and mounts are unfastened, the engine is removed with the transaxle attached-front wheel drive

     
    Transaxle mounting bolts
     
    Transaxle from the engine
     

  28.  

To install:

  1. Installation is the reverse of the removal procedure. Note the following important steps.


  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 new circlips on the inner CV-joint stub shafts, if equipped, and the intermediate shaft. Grease the shaft splines before installing the halfshaft/intermediate shaft into the transaxle.
  6.  
  7. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
  8.  
  9. Fill the engine and the transaxle with oil. 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.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Fresh air duct and the air cleaner/air flow meter assembly
     
    Transmission
     
    Accelerator cable from the throttle body
     
    Undercover
     
    Radiator hoses and the coolant reservoir hose
     
    Cooling fan electrical connector
     
    Transmission oil cooler hose, if equipped with automatic transmission
     
    Radiator/cooling fan assembly
     
    Accessory drive belts
     
    Power steering pump and move it aside without disconnecting the hydraulic hoses
     
    Air conditioner compressor and move it aside without disconnecting the refrigerant lines
     

  10.  
  11. Disconnect the following electrical connectors:

    Steering pressure sensor electrical connector
     
    Throttle position sensor electrical connector
     
    Idle air control valve electrical connector
     
    Heated Oxygen (HO 2 S) sensor electrical connector
     
    Ignition coil electrical connectors
     
    Crankshaft position sensor electrical connector
     
    Ground electrical connectors
     
    Fuel injector electrical connectors
     
    Alternator electrical connectors
     
    Oil pressure sensor electrical connector
     
    Starter electrical connectors
     

  12.  
  13. Disconnect the following hoses:

    Brake vacuum hose
     
    Fuel hose
     
    Purge control vacuum hose
     
    Cruise control vacuum hose
     
    Water inlet hose
     
    Heater hose
     
    Exhaust pipe from the exhaust manifold and install suitable lifting equipment onto the engine.
     
    Engine from the vehicle
     

  14.  

To install:

  1. Install or connect the following:

    Engine assembly by tilting the engine downward and aligning the engine mounts with the crossmember holes. Torque the nuts to 42-57 ft. lbs. (57-78 Nm)
     
    Exhaust pipe to the manifold using a new gasket. Torque the nuts to 34 ft. lbs. (46 Nm)
     

  2.  
  3. Connect the following hoses:

    Brake vacuum hose
     
    Fuel hose
     
    Purge control vacuum hose
     
    Cruise control vacuum hose
     
    Water inlet hose
     
    Heater hose
     

  4.  
  5. Connect the following electrical connectors:

    Steering pressure sensor electrical connector
     
    Throttle position sensor electrical connector
     
    Idle air control valve electrical connector
     
    HO 2 S electrical connector
     
    Ignition coil electrical connectors
     
    Crankshaft position sensor electrical connector
     
    Ground electrical connectors
     
    Fuel injector electrical connectors
     
    Alternator electrical connectors
     
    Oil pressure sensor electrical connector
     
    Starter electrical connectors
     

  6.  
  7. Install or connect the following:

    Air conditioner compressor and power steering pump
     
    Drive belt(s)
     
    Radiator and fans and all cooling system hoses
     
    Accelerator cable
     
    Air cleaner and air flow meter assembly
     
    Transmission
     
    Negative battery cable
     

  8.  
  9. Fill and bleed the cooling system.
  10.  
  11. Fill the engine and transmission.
  12.  
  13. Start the engine and check for leaks.
  14.  
  15. Check the ignition timing and idle speed.
  16.  

  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 cooling system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Radiator
     
    Accelerator cable and bracket from the throttle body
     
    Fuel hose
     
    Vacuum hoses and engine harness connectors
     
    Heater hose
     
    Accessory drive belts
     
    Power steering pump and move it aside without disconnecting the hydraulic hoses
     
    Air conditioner compressor and move it aside without disconnecting the refrigerant lines
     
    Transmission
     

  10.  
  11. Disconnect the following electrical connectors, if equipped:

    Steering pressure sensor electrical connector
     
    Throttle Position (TP) sensor electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Heated Oxygen (HO 2 S) sensor electrical connector
     
    Ignition coil electrical connectors
     
    Crankshaft Position (CKP) sensor electrical connector
     
    Ground electrical connectors
     
    Fuel injector electrical connectors
     
    Alternator electrical connectors
     
    Oil pressure sensor electrical connector
     
    Starter electrical connectors
     

  12.  
  13. Remove or disconnect the following:

    Exhaust pipe from the exhaust manifold and install suitable lifting equipment onto the engine.
     
    Engine from the vehicle
     

  14.  

To install:

  1. Install or connect the following:

    Engine assembly by tilting the engine downward and aligning the engine mounts with the crossmember holes. Torque the nuts to 42-57 ft. lbs. (57-78 Nm).
     
    Exhaust pipe to the manifold using a new gasket. Torque the nuts to 34 ft. lbs. (46 Nm).
     
    All vacuum hoses
     

  2.  
  3. Connect the following electrical connectors, if equipped:

    Steering pressure sensor electrical connector
     
    TP sensor electrical connector
     
    IAC valve electrical connector
     
    HO 2 S electrical connector
     
    Ignition coil electrical connectors
     
    CKP sensor electrical connector
     
    Ground electrical connectors
     
    Fuel injector electrical connectors
     
    Alternator electrical connectors
     
    Oil pressure sensor electrical connector
     
    Starter electrical connectors
     

  4.  
  5. Install or connect the following:

    Transmission
     
    Air conditioner compressor and power steering pump
     
    Drive belt(s)
     
    Any remaining vacuum hoses
     
    Radiator and fans and all cooling system hoses
     
    Accelerator cable and bracket
     
    Air cleaner assembly
     
    Negative battery cable
     

  6.  
  7. Fill and bleed the cooling system.
  8.  
  9. Fill the engine and transmission.
  10.  
  11. Start the engine and check for leaks.
  12.  
  13. Check the ignition timing and idle speed.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the plug hole plate by lifting off and removing the plug hole plate from the areas shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Plug hole plate locations-Mazda 3 models

  4.  
  5. Remove the air hose and air cleaner assembly.
  6.  
  7. Remove the battery cover, duct, clamp, battery and battery tray.
  8.  
  9. Relieve the fuel system pressure and disconnect the fuel hoses.
  10.  
  11. Remove the accelerator cable and bracket.
  12.  
  13. Remove the front wheels, under cover and splash shields.
  14.  
  15. Remove the A/C drive belt.
  16.  
  17. Remove the A/C compressor with the lines still attached and wire the compressor out of the way.
  18.  
  19. Drain the transaxle fluid.
  20.  
  21. Drain the coolant.
  22.  
  23. Disconnect the brake booster vacuum hose.
  24.  
  25. Remove the exhaust system member.
  26.  
  27. Remove the front crossmember, front stabilizer bar, lower control arm, steering gear and the No. 1 engine mount.
  28.  
  29. Remove the drive shafts.
  30.  
  31. Remove the coolant over flow tank with the hose attached and wire it to one side.
  32.  
  33. Remove the cooling fan assembly.
  34.  
  35. If equipped with an automatic transaxle, disconnect the transaxle fluid lines, selector cable and wiring harness.
  36.  
  37. If equipped with a manual transaxle, remove the shift cable and the clutch release cylinder with the line still attached.
  38.  
  39. Disconnect the heater hoses.
  40.  
  41. Remove the radiator hoses.
  42.  
  43. Remove the exhaust system main silencer.
  44.  
  45. Remove the main fuse block connector by releasing the tab in the order shown in the accompanying illustration and pulling the lock lever up and remove the connector.

    Click image to see an enlarged view

    Fig. Removing the main fuse block connector-Mazda 3 models

  46.  
  47. Secure the engine and transaxle using an engine jack and attachment as shown in the accompanying illustration and remove the No. 3 engine mount.
  48.  
  49. Remove the battery bracket.
  50.  
  51. Remove the No. 4 engine mount.
  52.  
  53. Remove the engine and transaxle assembly from the vehicle as an assembly.

    Click image to see an enlarged view

    Fig. Secure the engine and transaxle using an engine jack and attachment as shown before removing the No. 3 and No. 4 engine mounts-Mazda 3 models



    Click image to see an enlarged view

    Fig. Exploded view of the engine mounting-Mazda 3 models

  54.  

To install:

  1. Installation is the reverse of removal, please keep in mind the following:
  2.  
  3. When installing the No. 4 engine mount, secure the engine and transaxle using an engine jack and attachment as shown in the accompanying illustration. Install the No. 1 and No. 4 engine mounts, do not tighten the retainers at this time.
  4.  
  5. Use a new No. 4 mount bolt and tighten it to 61-87 ft. lbs. (83-113 Nm).
  6.  
  7. Tighten the No. 4 engine mount and battery bracket nuts and bolts in the sequence shown in the accompanying illustration. Tighten the retainers (1) to 32-45 ft. lbs. (44-61 Nm) and the retainers (2) to 61-86 inch lbs. (7-10 Nm).

    Click image to see an enlarged view

    Fig. Location of the No. 4 engine mount rubber bolt-Mazda 3 models



    Click image to see an enlarged view

    Fig. Tighten the No. 4 engine mount and battery bracket nuts and bolts in this sequence-Mazda 3 models



    Click image to see an enlarged view

    Fig. Location of the No. 3 engine mount bracket stud bolts-Mazda 3 models



    Click image to see an enlarged view

    Fig. Location of the No. 3 engine joint bracket nuts and bolts-Mazda 3 models



    Click image to see an enlarged view

    Fig. Tighten the No. 1 mount bolts in the sequence illustrated-Mazda 3 models

  8.  
  9. Tighten the No. 3 mount bracket stud bolts to 62-115 inch lbs. (7-13 Nm).
  10.  
  11. Tighten the No. 3 joint bracket nuts and bolts to 55-77 ft. lbs. (74-105 Nm).
  12.  
  13. Remove the jack and the attachment and tighten the No. 1 mount bolts in the sequence illustrated to 69-86 ft. lbs. (93-116 Nm).
  14.  
  15. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  16.  
  17. Connect the negative battery cable, start the engine and check for leaks.
  18.  
  19. Check the ignition timing and the idle speed.
  20.  
  21. Check all fluid levels.
  22.  
  23. Check the vehicle alignment.
  24.  

1.6L (Zm) Engine

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:

    Battery
     
    Air cleaner, air hose and resonance chamber
     
    Front exhaust pipe
     
    Accelerator cable and bracket
     
    Heater and vacuum hoses
     
    Radiator
     
    Drive belt
     
    Fuel hoses
     
    Any rods, pipes or cables related to the transaxle that would hinder removal
     
    Halfshafts
     
    Power steering pump with the lines still attached and set aside
     
    A/C compressor with the lines still attached and position aside
     
    Air cleaner bracket
     
    Battery carrier bracket
     

  12.  
  13. Support the engine with a suitable engine support device.

    Number 1 engine mount. Refer to the accompanying illustration for location.
     
    Number 2 engine mount nut A . Refer to the accompanying illustration for location.
     
    Engine mount member retainers. Refer to the accompanying illustration for location.
     
    Number 2 engine mount. Refer to the accompanying illustration for location.
     

  14.  
  15. Remove the engine support device and attach a hoist and chain to the engine.

    Number 4 engine mount. Refer to the accompanying illustration for location.
     
    Number 3 engine mount. 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-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Remove the number 2 engine mount nut retainersA, then the engine mount retainers-Protégé models equipped with the 1.6L (ZM) engine

     

  16.  

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:

    Tighten the number 3 engine mount bolt and nut in the sequence illustrated, then tighten the mount stay bolt and nut A . Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration.

    Click image to see an enlarged view

    Fig. Tighten the number 3 engine mount bolt and nut in this sequence and the mount stay boltA-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Number 4 engine mount retainer torque sequence on models with a manual transaxle-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Number 4 engine mount retainer torque sequence on models with a automatic transaxle-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Number 1 engine mount retainer torque sequence-Protégé models equipped with the 1.6L (ZM) engine

     
    Tighten the number 4 engine mount bolts A , then tighten bolts B . Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration.
     

  6.  
  7. Remove the hoist and chain and install the engine support device.

    Number 2 engine mount nut A , then tighten the mount member bolt and nut. Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration.
     
    Number 1 engine mount bolts A and then the bolt B . Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Battery carrier bracket
     
    Air cleaner bracket
     
    A/C compressor
     
    Power steering pump
     
    Halfshafts
     
    Any rods, pipes or cables related to the transaxle that were removal
     
    Fuel hoses
     
    Drive belt
     
    Radiator
     
    Heater and vacuum hoses
     
    Accelerator cable and bracket
     
    Front exhaust pipe
     
    Air cleaner, air hose and resonance chamber
     
    Battery
     

  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.  

1.8L (Fp) Engine

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
     
    Accelerator cable
     
    Fuel hoses
     
    Front exhaust pipe
     
    Any rods, pipes or cables related to the transaxle that would hinder removal
     
    Battery
     
    Fuse box
     
    Drive belt
     
    Power steering pump with the lines still attached and set aside
     
    A/C compressor with the lines still attached and position aside
     
    Halfshafts
     

  12.  
  13. Support the engine with a suitable engine support device.

    Engine mount member retainers
     
    Number 3 engine mount. Refer to the accompanying illustration for location.
     
    Number 4 engine mount. Refer to the accompanying illustration for location.
     
    Number 1 engine mount. Refer to the accompanying illustration for location.
     
    Number 2 engine mount. Refer to the accompanying illustration for location.
     

  14.  
  15. Remove the engine support device and attach a hoist and chain to the engine.

    Engine and transaxle assembly from the vehicle.
     

  16.  


    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications-Protege models equipped with the 1.8L (FP) engine


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:

    Engine and transaxle assembly
     
    Number 2 engine mount . Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 1 engine mount. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Hand tighten the number 3 and 4 engine mount boltsA-MA-GH-M
     
    Engine mount member. Tighten the fasteners to the specifications shown in the accompanying illustration and remove the support device.
     


    Click image to see an enlarged view

    Fig. Number 3 and 4 engine mount retainer torque sequence-Protege models equipped with the 1.8L (FP) engine

    Halfshafts
     
    Power steering pump
     
    A/C compressor
     
    Fuse box
     
    Battery
     
    Any rods, pipes or cables related to the transaxle that were removed
     
    Front exhaust pipe
     
    Fuel hoses
     
    Accelerator cable
     
    Air cleaner
     
    Radiator
     
    Drive belt
     
    Negative battery cable
     

  6.  
  7. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  8.  
  9. Connect the negative battery cable, start the engine and check for leaks.
  10.  
  11. Check the ignition timing and the idle speed.
  12.  
  13. Check all fluid levels.
  14.  

 
label.common.footer.alt.autozoneLogo