Mazda Car 2002-04

Engine 2

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Removal & Installation



2.0L (Fs) 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 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.  


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
     
    Halfshafts
     
    Roll dampener
     

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

    Engine mount member retainers. Refer to the accompanying illustration for location.
     
    Number 3 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.
     
    Number 4 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 2.0L (FS) engine



    Click image to see an enlarged view

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



    Click image to see an enlarged view

    Fig. Assemble the roll damper as illustrated-Protégé models equipped with the 2.0L (FS) engine

     

  14.  

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 the number 4 engine mount. Tighten the fasteners to the specifications shown in the accompanying illustration as follows:
    1. Hand tighten the number 3 and 4 engine mount bolts and nuts A-M .
    2.  
    3. Tighten the number 4 engine mount bolts and nuts A-H .
    4.  
    5. Tighten the number 3 engine mount bolts and nuts I-N .
    6.  
    7. Measure the number 4 mount clearance which should be 0.12-0.15 inch (3-4mm). If not within specification, loosen the nuts and bolts and re-torque using the same procedure.
    8.  

  6.  
  7. Install or connect the following:

    Number 1 engine mount. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Number 3 engine mount, refer to the number 4 mount tightening sequence. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Engine mount member. Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Roll damper, refer to the illustration or proper assembly.

    Click image to see an enlarged view

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

     
    Halfshafts. 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.
     
    A/C compressor
     
    Power steering pump
     
    Fuse box
     
    Battery
     
    Any rods, pipes or cables related to the transaxle
     
    Front exhaust pipe. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
     
    Fuel hoses
     

  8.  
  9. 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 0.04-0.11 inch (1-3mm) 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.
    12.  

  10.  
  11. Install or connect the following:

    Air cleaner assembly
     
    Radiator
     
    Negative battery cable
     

  12.  
  13. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  14.  
  15. Connect the negative battery cable, start the engine and check for leaks.
  16.  
  17. Check the ignition timing and the idle speed.
  18.  
  19. Check all fluid levels.
  20.  

2.3L (Kj) 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:

    Hood
     
    Front wheels
     
    Air cleaner assembly
     
    Intake manifold cover
     
    Splash shield
     
    Charge air cooler duct
     
    Battery clamp, cover, battery, battery carrier and battery air duct
     
    Air duct
     
    Accelerator cable
     
    Dust cover
     
    Drive belt
     
    Crankshaft and vacuum pump pulleys
     
    A/C compressor with the lines still attached and position aside
     
    Power steering pump with the lines still attached and position aside
     
    Radiator grille
     
    Upper seal board
     
    Radiator reservoir
     
    Cooling fan connector and fan
     
    Condenser fan motor connector and the fan
     
    Oil cooler hose
     
    Radiator hose, bracket and the radiator
     
    Selector cable
     
    Front exhaust pipe
     
    Upper and lower ball joints
     
    Halfshafts
     
    Joint shaft
     

  12.  
  13. Support the engine using a suitable support device.
    CAUTION
    Engine load can damage the number 4 mount bolts holes when removing the bolts so make sure all weight is off the mount.



    Number 1 engine mount bracket. Refer to the accompanying illustration for location.
     
    Engine mount member retainers. Remove the bolts A first and then the bolts B and remove the member. Refer to the accompanying illustration for location.
     

  14.  
  15. Attach a hoist to the engine, take the weight of the engine with the hoist and remove the engine support device, Lift up the engine/transaxle assembly slightly until the number 3 and 4 mounts are free from engine weight.

    Number 4 engine mount bracket. Refer to the accompanying illustration for location.
     
    Number 3 engine mount sub bracket. Refer to the accompanying illustration for location.
     
    Engine and transaxle assembly from the vehicle. Be careful the powertrain assembly does not swing and strike the vehicle causing damage

    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications (part 1 of 4)-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications (part 2 of 4)-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications (part 3 of 4)-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications (part 4 of 4)-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Remove the boltsAfirst and then the boltsBand remove the engine mount member-Millenia models equipped with the 2.3L (KJ) 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:

    Number 4 engine bracket retainers and hand tighten the retainers
     

  6.  
  7. Using the hoist lower the powertrain assembly and hand tighten the number 3 mount sub bracket retainers

    Number 4 engine bracket retainers and tighten the bolts E to 44 ft. lbs. (60 Nm) and hand tighten bolts F .

    Click image to see an enlarged view

    Fig. Tighten the number 4 engine bracket retainersEto specification and hand tighten boltsF-Millenia models equipped with the 2.3L (KJ) engine

     

  8.  
  9. Remove the engine hoist and install the engine support device
  10.  
  11. Install the engine mount member and tighten bolts B to 68 ft. lbs. (93 Nm) and hand tighten bolts A .
  12.  
  13. Install the number 1 bracket and tighten the retainers to 77 ft. lbs. (104 Nm) and remove the engine support.
  14.  
  15. Install the number 1 engine mount stay and tighten retainers G to 68 inch lbs. (10 Nm) and H to 77 ft. lbs. (104 Nm).

    Click image to see an enlarged view

    Fig. Tighten the number 1 engine mount stay retainersGandHto specification-Millenia models equipped with the 2.3L (KJ) engine

  16.  
  17. Tighten the number 2 engine mount bolts A to 77 ft. lbs. (104 Nm).
  18.  
  19. Tighten the number 3 engine mount sub bracket nuts D to 77 ft. lbs. (104 Nm).
  20.  
  21. Tighten the number 4 engine mount nuts and bolts C and F to 68 ft. lbs. (93 Nm)

    Click image to see an enlarged view

    Fig. Tighten the number 2 engine mount boltsAto specification-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Tighten the number 3 engine mount sub bracket nutsDto specification-Millenia models equipped with the 2.3L (KJ) engine



    Click image to see an enlarged view

    Fig. Tighten the number 4 engine mount nuts and boltsCandFto specification-Millenia models equipped with the 2.3L (KJ) engine

  22.  
  23. Install or connect the following:

    Joint shaft. Install a new circlip with the opening facing up. Tighten the bolts to 32-45 ft. lbs. (43-61 Nm).
     
    Halfshafts. 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.
     
    Ball joints
     
    Front pipe
     
    Selector cable
     

  24.  
  25. Power steering pump

    A/C Compressor
     
    Drive belt
     

  26.  
  27. When connecting the accelerator cable, perform the following adjustment:
    1. Measure the free play of the cable, it should be 0.04-0.11 inch (1-3mm), if not turn adjustment nut A until the specification is reached.
    2.  
    3. Fully depress the accelerator pedal and check the throttle is wide open, if not adjust using nut B .

      Click image to see an enlarged view

      Fig. Accelerator cableAand throttle cableBadjustment nuts-Millenia models equipped with the 2.3L (KJ) engine

    4.  

  28.  
  29. Install the remaining components in the reverse of removal.
  30.  
  31. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  32.  
  33. Connect the negative battery cable, start the engine and check for leaks.
  34.  
  35. Check the ignition timing and the idle speed.
  36.  
  37. Check all fluid levels.
  38.  

2.3L (L3) Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the shroud panel.
  6.  
  7. Remove the radiator.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Remove the plug hole plate.

    Click image to see an enlarged view

    Fig. Plug hole plate assembly-Mazda 6 with 2.3L (L3) engine

  12.  
  13. Remove the power steering pump with the lines attached and set aside.
  14.  
  15. Remove the A/C compressor with the lines still attached and wire the compressor out of the way.
  16.  
  17. Remove the joint shaft as follows:
    1. Remove the ABS sensor.
    2.  
    3. Separate the tie rod ends from the knuckle.
    4.  
    5. Remove the damper fork bolt.
    6.  
    7. Separate the lower control arm front and rear ball joints.
    8.  
    9. Remove the stabilizer bar link nut and the link from the damper fork.
    10.  
    11. Remove the joint shaft bracket bolt.
    12.  
    13. Remove the halfshafts.
    14.  
    15. Disconnect the right halfshaft from the joint shaft by tapping the transaxle side outer ring with a brass bar and a hammer. Disconnect the joint shaft bracket from the block and remove the joint shaft.
    16.  
    17. Install tool 49 G030 455 to hold the side gears after removal.

      Click image to see an enlarged view

      Fig. Exploded view of the joint shaft assembly-Mazda 6 models with the 2.3L (L3) engine

    18.  

  18.  
  19. Remove the air cleaner assembly, air intake duct, bracket and vacuum hoses.
  20.  
  21. On models with a automatic transaxle, disconnect the transmission fluid hose and the selector cable.
  22.  
  23. Remove the vacuum and heater hoses
  24.  
  25. If equipped with a manual transaxle, remove the control cable and the clutch release cylinder with the line still attached.
  26.  
  27. Relieve the fuel system pressure and disconnect the fuel hoses.
  28.  
  29. Disconnect the wring harness at the engine side.
  30.  
  31. Remove the front exhaust pipe.
  32.  
  33. Remove the No. 1 mount rubber bolt A on the engine mount bracket side, loosen bolt B on the crossmember side until about 3 pitches are showing. DO NOT remove the N0, 1 mount rubber from the vehicle.

    Click image to see an enlarged view

    Fig. Exploded view of the engine mounting-Mazda 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Locations of bolts A and B on the No. 1 mount rubber-Mazda 6 models with the 2.3L (L3) engine

  34.  
  35. Remove the No. 1 engine mount bracket.
  36.  
  37. Secure the engine and transaxle using a hoist.
  38.  
  39. Remove the No. 4 mount bracket and rubber as a unit.
  40.  
  41. Remove the engine ground.
  42.  
  43. Remove the No. 3 engine joint bracket.
  44.  
  45. Remove the engine and transaxle from the vehicle as an assembly.
  46.  
  47. Remove the engine-to-transaxle bolts and separate the engine from the transaxle.
  48.  

To install:

  1. Installation is the reverse of removal, please keep in mind the following:
  2.  
  3. On models with an automatic transaxle, tighten the engine-to-transaxle bolts to 28-38 ft. lbs. (37-52 Nm)
  4.  
  5. On models with a manual transaxle, tighten the engine-to-transaxle bolts to 28-36 ft. lbs. (37-50 Nm)
  6.  
  7. When installing the No. 3 engine joint bracket, tighten the mount bracket stud bolt to 62-115 inch lbs. (7-13 Nm) and the joint bracket bolt and nut in the order illustrated to 55-76 ft. lbs. (74-105 Nm).

    Click image to see an enlarged view

    Fig. No. 3 engine mount bracket stud bolt locations-Mazda 6 models with the 2.3L (L3) engine



    Click image to see an enlarged view

    Fig. Tighten the No. 3 joint bracket bolt and nut in the order shown-Mazda 6 models with the 2.3L (L3) engine

  8.  
  9. Install the No. 4 engine mount bracket and rubber. Tighten the No. 4 mount bracket and rubber bolts and nuts in the order illustrated as follows:
    1. Bolts numbered 1, 2 and 3: 43-58 ft. lbs. (58-80 Nm).
    2.  
    3. Bolts numbered 4, 5 and 6: 49-68 ft. lbs. (66-93 Nm).

      Click image to see an enlarged view

      Fig. Tighten the No. 4 mount bracket and rubber bolts and nuts in the order shown-Mazda 6 models with the 2.3L (L3) engine

    4.  

  10.  
  11. Install the No. 1 engine mount bracket as follows:
    1. Install and tighten bolt A to 68-86 ft. lbs. (93-116 Nm). refer to the illustration for bolt location.
    2.  
    3. Install and tighten bolt B to 68-86 ft. lbs. (93-116 Nm). refer to the illustration for bolt location.

      Click image to see an enlarged view

      Fig. Tighten the No. 1 mount bracket bolts in the order shown-Mazda 6 models with the 2.3L (L3) engine



      Click image to see an enlarged view

      Fig. Tighten the No. 1 mount rubber bolts in the order shown-Mazda 6 models with the 2.3L (L3) engine

    4.  

  12.  
  13. Install the No. 1 engine mount rubber as follows:
    1. Install and tighten bolt A to 63-85 ft. lbs. (85-116 Nm). refer to the illustration for bolt location.
    2.  
    3. Install and tighten bolt B to 68-86 ft. lbs. (93-116 Nm). refer to the illustration for bolt location.
    4.  

  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.  

 
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