Mazda 3 manuals

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

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

WARNING:

CAUTION:

NOTE:

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:



1

Battery tray bracket

2

No.1 engine mount rubber, front crossmember component

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

(See Engine Mount Installation Note.)

3

No.4 engine mount rubber

(See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.)

(See Engine Mount Installation Note.)

4

No.3 engine mount

(See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.)

(See Engine Mount Installation Note.)

5

Engine, transaxle


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:

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


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:


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



No.

Tightening torque

1

75104 Nm {7.710 kgfm, 5676 ftlbf}

2

7193 Nm {7.39.4 kgfm, 5368 ftlbf}


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


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


CAUTION:

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Other materials:

Volume/Display/Sound Controls
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Front Door Trim Removal/Installation
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Crankshaft Position (CKP) Sensor Inspection [Mzr 2.0, Mzr 2.5]
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