Mazda RX-8 2004-06

Engine

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Removal & Installation




NOTE
The procedure for pulling the engine requires removing the transmission and front crossmember along with it. A suitable support fixture that will support the entire assembly must be used for removal.

  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 transmission fluid.
  8.  
  9. Drain the cooling system.
  10.  
  11. Place the front wheels in the straight ahead position.
  12.  
  13. Raise and support the vehicle.
  14.  
  15. Remove or disconnect the following:

    Front wheels
     
    Engine cover

    Click image to see an enlarged view

    Fig. Remove the engine cover in the order shown

     
    Rear engine cross brace
     
    Battery cover, battery, box and tray
     
    Air cleaner, intake duct and insulator
     
    Powertrain Control Module (PCM)
     
    Secondary Air Injection (AIR) pump
     
    Brake vacuum hose
     
    Charcoal canister connector
     
    Fuel lines
     
    Ignition coil
     
    Accessory drive belts
     
    A/C compressor and wire aside
     
    Engine wiring harness from main fuse block
     
    Engine splash shield
     
    ABS speed sensor connector
     
    Radiator, heater and coolant tank hoses
     
    Selector link on automatic transmission
     
    Manual transmission shift lever
     
    Clutch slave cylinder and wire aside
     
    Steering shaft pinch bolt. Refer to the accompanying illustration for location.
     
    Oil lines. Refer to the accompanying illustration for location.
     
    Transmission cooler lines. Refer to the accompanying illustration for location.
     
    Brake caliper. Refer to the accompanying illustration for location.
     
    Lower strut bolt. Refer to the accompanying illustration for location.
     
    Rear crossmembers. Refer to the accompanying illustration for location.
     
    Catalytic converter and exhaust system. Refer to the accompanying illustration for location.
     
    Heat insulator. Refer to the accompanying illustration for location.
     
    Driveshaft. Refer to the accompanying illustration for location.
     
    Front crossmember. Refer to the accompanying illustration for location.
     
    Power plant frame. Refer to the accompanying illustration for location.
     
    Engine, transmission and front suspension frame assembly
     

  16.  
  17. Use an engine hoist and separate the engine/transmission assembly from the front suspension crossmember using the steps shown in the accompanying illustration.

    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications-RX-8 1.3L engine



    Click image to see an enlarged view

    Fig. Separating the engine/transmission assembly from the front crossmember- RX-8 1.3L engine

  18.  

To install:

  1. Installation is the reverse of removal. Tighten the fasteners to the specifications shown in the accompanying illustrations.
  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. Fill the engine and the transmission with the proper type and amount of fluids. Fill the cooling system.
  6.  
  7. Connect the battery cables.
  8.  
  9. On models with dynamic suspension, perform the steering angle sensor initialization procedure.
  10.  
  11. Check the ignition timing and the idle speed.
  12.  
  13. Check the front wheel alignment.
  14.  
  15. Check all fluid levels.
  16.  

 
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