Mazda 3 Service Manual: Engine Removal/Installation [Mzr 2.3 Disi Turbo]

WARNING:

• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”..

CAUTION:

• Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

NOTE:

• Perform the engine and transaxle component removal/installation from below the vehicle.

1. Remove the battery cover..

2. Disconnect the negative battery cable..

3. Remove the charge air cooler cover..

4. Remove the PCM cover No.1..

5. Disconnect the PCM connector..

6. Remove the battery tray and PCM component..

7. Remove the air cleaner component..

8. Remove the front wheels and tires..

9. Remove the aerodynamic under cover No.2 and splash shield as a single unit..

10. Drain the transaxle oil..

11. Drain the engine coolant..

12. Remove the coolant reserve tank..

13. Disconnect the upper radiator hose..

14. Remove the lower radiator hose and pipe component..

15. Disconnect the heater hose..

16. Disconnect the fuel hose..

17. Disconnect the evaporative hose..

18. Disconnect the brake vacuum hose..

19. Disconnect the power steering pipe component and then drain the power steering fluid..

20. Disconnect the shift cable..

21. Remove the clutch release cylinder with the pipe still connected..

22. Remove the TWC..

23. Disconnect the front drive shafts from the engine side, set the drive shafts out of the way..

24. Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way..

25. Remove the wiring harness installation bolt and nut shown in the figure.

26. Disconnect the connectors and the wiring harnesses related to the engine removal/installation.

27. Remove in the order indicated in the table.

28. Install in the reverse order of removal.

29. Start the engine, and inspect and adjust the following:

• Front wheel alignment.

• Power steering fluid air bleeding.

• Cooling system air bleeding.

• Leakage of engine oil, engine coolant, transaxle oil, and fuel.

• Runout and contact of pulley and belt.

• Ignition timing, idle speed and idle mixture..

• Engine-driven accessories operation.

No.1 Engine Mount Rubber, Front Crossmember Component Removal Note

1. Loosen the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure.

2. Remove the No.1 engine mount rubber installation bolt (No.1 engine mount bracket side) shown in the figure.

3. Remove the No.1 engine mount rubber and the front crossmember component as a single unit..

No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note

1. Secure the engine and the transaxle using an engine jack.

Engine Mount Installation Note

NOTE:

• Retighten the No.3 engine mount stud bolts when the No.3 engine mount nuts are loosened.

1. Tighten the No. 3 engine mount stud bolts.

Tightening torque

• 7—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

2. Secure the engine and transaxle using an engine jack.

3. Temporarily tighten the No.3 engine mount installation bolts and nuts.

4. Temporarily tighten the No.4 engine mount rubber installation bolt as shown in the figure.

5. Install the No.1 engine mount rubber and the front crossmember component as a single unit..

6. Temporarily tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.

CAUTION:

• Install the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.

Bolt stem length

• Front crossmember side: 62mm {2.4 in}

• No.1 engine mount bracket side: 65mm {2.6 in}

7. Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.

8. Tighten the No.4 engine mount rubber installation bolt.

Tightening torque

• 94—152 N·m {9.6—15 kgf·m, 70—112 ft·lbf}

9. Tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.

CAUTION:

• Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.

Tightening torque

• 73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}