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Home › Mazda › 2002 › B4000 Base, Automatic › Repair and Diagnosis › External Pages › Different car › Section 97 (Engine Mechanical) › Engine Removal/Installation

Engine Removal/Installation

WARNING: This page is about a different car, the 2002 Mazda B2300 and 2001 Mazda B2300. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the fuel pressure. See FUEL SYSTEM PRESSURE RELEASE .
  2. Disconnect the negative battery cable.
  3. Recover the A/C system. See A/C SYSTEM PERFORMANCE .
  4. Drain the engine cooling system. See ENGINE COOLANT REPLACEMENT .
  5. Drain the engine oil.
  6. Remove the hood.
  7. Remove the accelerator control snow shield.
    Fig 1: Removing Accelerator Control Snow Shield
    G01168059Courtesy of MAZDA MOTORS CORP.
  8. Remove the air cleaner tube.
  9. Remove the upper radiator hose.
    Fig 2: Removing Upper Radiator Hose
    G01168060Courtesy of MAZDA MOTORS CORP.
  10. Remove the lower radiator hose.
    Fig 3: Removing Lower Radiator Hose
    G01168061Courtesy of MAZDA MOTORS CORP.
  11. Remove the fan and shroud. See ELECTRIC COOLING FAN REMOVAL/INSTALLATION .
  12. Disconnect the Powertrain Control Module (PCM) electrical connector. Remove the retaining nut on the harness clamp. Position the harness on the engine.
    Fig 4: Disconnecting PCM Electrical Connector
    G01168062Courtesy of MAZDA MOTORS CORP.
  13. Remove the ground stud for the PCM.
    Fig 5: Disconnecting PCM Ground Stud
    G01168063Courtesy of MAZDA MOTORS CORP.
  14. Remove the heater hose assembly.
    1. Disconnect the heater water hoses at the bulk-head.
    2. Disconnect the vacuum hose.
    3. Disconnect the heater water hoses at the engine and remove the assembly.
    Fig 6: Removing Heater Hose Assembly
    G01168064Courtesy of MAZDA MOTORS CORP.
  15. Disconnect the vacuum hose to the vacuum reservoir.
    Fig 7: Disconnecting Vacuum Reservoir Vacuum Hose
    G01168065Courtesy of MAZDA MOTORS CORP.
  16. Disconnect the engine-to-coolant reservoir bypass hose.
    Fig 8: Disconnecting Engine-To-Coolant Reservoir Bypass Hose
    G01168066Courtesy of MAZDA MOTORS CORP.
  17. Disconnect the coolant reservoir-to-engine supply hose.
    Fig 9: Disconnecting Coolant Reservoir-To-Engine Supply Hose
    G01168067Courtesy of MAZDA MOTORS CORP.
  18. Disconnect the A/C compressor clutch.
    Fig 10: Disconnecting A/C Compressor Clutch Electrical Connector
    G01168068Courtesy of MAZDA MOTORS CORP.
  19. Disconnect the Mass Airflow Sensor (MAF) electrical connector.
    Fig 11: Disconnecting MAF Sensor Electrical Connector
    G01168069Courtesy of MAZDA MOTORS CORP.
  20. Disconnect the A/C compressor manifold, plug the lines and the compressor ports.
    Fig 12: Disconnecting A/C Compressor Manifold
    G01168070Courtesy of MAZDA MOTORS CORP.
  21. Position the accelerator and cruise control cables aside.
    1. Disconnect the accelerator cable and cruise control cable (if so equipped) from the throttle linkage.
    2. Disconnect the accelerator cable and cruise control cable (if so equipped) from the mounting bracket and position out of the way.
    Fig 13: Disconnecting Accelerator & Cruise Control Cables
    G01168071Courtesy of MAZDA MOTORS CORP.
  22. Disconnect the power steering return hose.
    Fig 14: Disconnecting Power Steering Return Hose
    G01168072Courtesy of MAZDA MOTORS CORP.
  23. Disconnect the following:
    1. The Power Steering Pressure (PSP) switch electrical connector.
    2. The high pressure power steering hose.
    3. Position the hose out of the way.
    Fig 15: Disconnecting PSP Switch Electrical Connector & High Pressure Power Steering Hose
    G01168073Courtesy of MAZDA MOTORS CORP.
  24. Remove the fuel line clip and using the special tool, disconnect the fuel supply hose.
    Fig 16: Disconnecting Fuel Supply Hose
    G01168074Courtesy of MAZDA MOTORS CORP.
  25. Disconnect the following:
    1. 42-pin electrical connector.
    2. EVAP canister purge valve supply hose.
    3. Evaporative purge hose.
    Fig 17: Disconnecting 42-Pin Electrical Connector, EVAP Canister Purge Valve Supply Hose & Evaporative Purge Hose
    G01168075Courtesy of MAZDA MOTORS CORP.
  26. Disconnect the brake booster vacuum hose and the engine ground strap.
    Fig 18: Disconnecting Brake Booster Vacuum Hose & Engine Ground Strap
    G01168076Courtesy of MAZDA MOTORS CORP.
  27. Disconnect the positive battery cable. Disconnect the negative battery cable. Disconnect the solenoid control wire at the starter.
    Fig 19: Disconnecting Battery Cables & Solenoid Control Wire
    G01168077Courtesy of MAZDA MOTORS CORP.
  28. Remove the starter wiring harness clamp bolt and position it out of the way.
    Fig 20: Disconnecting Starter Wiring Harness Clamp
    G01168078Courtesy of MAZDA MOTORS CORP.
  29. Raise the vehicle on a hoist.
  30. Position the RH splash shield out of the way.
    Fig 21: Disconnecting RH Splash Shield
    G01168079Courtesy of MAZDA MOTORS CORP.
  31. Disconnect the alternator electrical connections.
    Fig 22: Disconnecting Alternator Electrical Connections
    G01168080Courtesy of MAZDA MOTORS CORP.
  32. Disconnect the block heater electrical connector.
    Fig 23: Disconnecting Block Heater Electrical Connector
    G01168081Courtesy of MAZDA MOTORS CORP.
  33. Disconnect the front Heated Oxygen Sensor (HO2S) electrical connector at the bell housing.
    Fig 24: Disconnecting Front HO2S Electrical Connector
    G01168082Courtesy of MAZDA MOTORS CORP.
  34. Disconnect the oil pressure sensor electrical connector
    Fig 25: Disconnecting Oil Pressure Sensor Electrical Connector
    G01168083Courtesy of MAZDA MOTORS CORP.
  35. Disconnect the engine wiring pushpins and position the engine wiring harnesses out of the way.
    Fig 26: Disconnecting Engine Wiring Pushpins
    G01168084Courtesy of MAZDA MOTORS CORP.
  36. Remove the engine oil filter.
    Fig 27: Removing Engine Oil Filter
    G01168085Courtesy of MAZDA MOTORS CORP.
  37. If the vehicle is equipped with an automatic transmission, remove the bolt retaining the transmission cooling tubes to the engine. Remove the bracket.
    Fig 28: Removing Transmission Cooling Tube Bracket
    G01168086Courtesy of MAZDA MOTORS CORP.
  38. Remove the transmission dust shield.
    Fig 29: Removing Transmission Dust Shield
    G01168087Courtesy of MAZDA MOTORS CORP.
  39. Remove the exhaust flange nuts.
    Fig 30: Removing Exhaust Flange Nuts
    G01168088Courtesy of MAZDA MOTORS CORP.
  40. Remove the starter motor. See STARTER MOTOR - 2.3L .
  41. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector at the rear of the transmission.
    Fig 31: Removing HO2S Electrical Connector
    G01168089Courtesy of MAZDA MOTORS CORP.
  42. Disconnect the transmission wiring harness.
    1. Disconnect the vehicle speed sensor, transmission range sensor, backup light switch and the transmission electrical connectors.
    2. Disconnect the pushpins and position the harness forward to the engine.
      3. Fig 32: Disconnecting Transmission Wiring Harness
      G01168090Courtesy of MAZDA MOTORS CORP.
  43. Remove the oil filter adapter.
    Fig 33: Removing Oil Filter Adapter
    G01168091Courtesy of MAZDA MOTORS CORP.
    44. NOTE: Leave two side bolts in until the engine is ready to be removed.
    Fig 34: Removing Transmission-To-Engine Bolts
    G01168092Courtesy of MAZDA MOTORS CORP.
  44. Remove nine of the transmission-to-engine bolts.
  45. Lower the vehicle.
  46. On vehicles equipped with an automatic transmission, remove the transmission fluid indicator and tube assembly.
    Fig 35: Removing Transmission Fluid Indicator & Tube Assembly
    G01168093Courtesy of MAZDA MOTORS CORP.
  47. Remove the starter dust shield.
    Fig 36: Removing Starter Dust Shield
    G01168094Courtesy of MAZDA MOTORS CORP.
    48. NOTE: Mark one stud and the flexplate for assembly reference.
    Fig 37: Removing Torque Converter Nuts
    G01168095Courtesy of MAZDA MOTORS CORP.
  48. On vehicles equipped with an automatic transmission, remove the four torque converter nuts.
  49. Support the transmission with a floor jack.
  50. Support the engine with the Floor Crane using the Spreader Bar.
  51. Remove the two side transmission-to-engine bolts.
    52. NOTE: Left side shown, right side similar.
    Fig 38: Removing Engine Support Insulators
    G01168096Courtesy of MAZDA MOTORS CORP.
  52. Remove the four engine support insulators.
  53. Remove the engine from the vehicle.
  54. On vehicles equipped with a manual transmissions, remove the clutch. See CLUTCH DISC AND COVER REMOVAL/INSTALLATION .
  55. Remove the flywheel. For additional information refer to FLYWHEEL REMOVAL/INSTALLATION .
    Fig 39: Removing Flywheel
    G01168097Courtesy of MAZDA MOTORS CORP.
  56. Mount the engine on a suitable work stand.
  57. Install in the reverse order of removal.
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