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Home › Mazda › 2003 › Tribute DX, 4WD › Repair and Diagnosis › Engine Mechanical › Engine Mechanical - 2.0L › Engine Disassembly › Disassembly

Engine Disassembly: Disassembly

CAUTION: The engine sealing surfaces are soft metals. Do not use abrasive grinding discs to remove gasket material; use only manual scrapers. Do not scratch or gouge the aluminum sealing surfaces.
  1. Remove the bolt and the oil level indicator and tube.
    Fig 1: Removing Oil Level Indicator & Tube
    G02170772Courtesy of MAZDA MOTORS CORP.
  2. Remove the six bolts and three nuts and remove the exhaust manifold.
    • Discard the gasket.
    Fig 2: Exhaust Manifold Bolt Removal Sequence
    G02170773Courtesy of MAZDA MOTORS CORP.
  3. Remove the power steering pump bracket.
    Fig 3: Removing Power Steering Pump Bracket
    G02170774Courtesy of MAZDA MOTORS CORP.
  4. Remove the A/C compressor bracket.
    Fig 4: Removing A/C Compressor Bracket
    G02170775Courtesy of MAZDA MOTORS CORP.
  5. Remove the coolant tube.
    1. Remove the bolt and nut.
    2. Disconnect the hose.
    Fig 5: Removing Coolant Tube
    G02170776Courtesy of MAZDA MOTORS CORP.
  6. Remove the Crankshaft Position (CKP) sensor.
    Fig 6: Removing Crankshaft Position Sensor
    G02170777Courtesy of MAZDA MOTORS CORP.
  7. Remove the catalytic converter bracket.
    Fig 7: Removing Catalytic Converter Bracket
    G02170778Courtesy of MAZDA MOTORS CORP.
  8. Remove the crankcase vent oil separator.
    1. Disconnect the Positive Crankcase Ventilation (PCV) valve.
    2. Remove the bolts and remove the separator.
      • Discard the gasket.
    Fig 8: Removing Crankcase Vent Oil Separator
    G02170779Courtesy of MAZDA MOTORS CORP.
  9. Remove the coolant tube.
    1. Remove the bolt.
    2. Disconnect the hose.
    Fig 9: Removing Coolant Tube
    G02170780Courtesy of MAZDA MOTORS CORP.
  10. Remove the bolt and remove the crankshaft pulley.
    Fig 10: Removing Crankshaft Pulley
    G02170781Courtesy of MAZDA MOTORS CORP.
  11. Remove the accessory drive belt idler pulley.
    Fig 11: Removing Accessory Drive Belt Idler Pulley
    G02170782Courtesy of MAZDA MOTORS CORP.
  12. Remove the lower timing belt cover.
    Fig 12: Removing Lower Timing Belt Cover
    G02170783Courtesy of MAZDA MOTORS CORP.
  13. Remove the lower engine mount bracket.
    Fig 13: Removing Lower Engine Mount Bracket
    G02170784Courtesy of MAZDA MOTORS CORP.
  14. Remove the upper timing belt cover.
    Fig 14: Removing Upper Timing Belt Cover
    G02170785Courtesy of MAZDA MOTORS CORP.
  15. Remove the timing belt tensioner and the timing belt.
    Fig 15: Removing Timing Belt Tensioner & Timing Belt
    G02170786Courtesy of MAZDA MOTORS CORP.
  16. Remove the water pump adapter.
    Fig 16: Removing Water Pump Adapter
    G02170787Courtesy of MAZDA MOTORS CORP.
  17. Remove the timing belt idler pulley.
    Fig 17: Removing Timing Belt Idler Pulley
    G02170788Courtesy of MAZDA MOTORS CORP.
  18. Remove the ignition wires from the spark plugs.
    Fig 18: Removing Ignition Wires From Spark Plugs
    G02170789Courtesy of MAZDA MOTORS CORP.
  19. Remove the valve cover. Refer to VALVE COVER .
    1. Remove the studbolts.
    2. Remove the bolts.
    Fig 19: Removing Valve Cover
    G02170790Courtesy of MAZDA MOTORS CORP.
    20. CAUTION: The camshaft alignment tool is not recommended to hold the camshafts in place when removing or tightening the bolts. Damage to camshaft may result.
    NOTE: Use SST 303-098 to keep each camshaft from rotating.
    Fig 20: Removing Camshaft Timing Sprockets
    G02170791Courtesy of MAZDA MOTORS CORP.
  20. Remove the bolts and the camshaft timing sprockets.
    21. CAUTION: Cylinder head camshaft journal caps are numbered on the outside flats to make sure that they are assembled in their original positions. Failure to do so may result in engine damage.
    Fig 21: Camshaft Cap Bolt Removal Sequence
    G02170792Courtesy of MAZDA MOTORS CORP.
  21. Remove the camshafts.
    1. Loosen the camshaft journal cap bolts in several two-turn passes in the sequence shown.
    2. Remove the bolts.
    3. Remove the caps.
    22. CAUTION: If the camshaft and valve tappets are to be reused, mark the location of the valve tappets to make sure that they are assembled in their original positions.
    Fig 22: Removing Valve Tappets
    G02170793Courtesy of MAZDA MOTORS CORP.
  22. Remove the valve tappets from the cylinder head.
  23. Remove the inner timing belt cover.
    Fig 23: Removing Inner Timing Belt Cover
    G02170794Courtesy of MAZDA MOTORS CORP.
  24. Remove the generator.
    Fig 24: Removing Generator
    G02170795Courtesy of MAZDA MOTORS CORP.
  25. Remove the generator bracket.
    Fig 25: Removing Generator Bracket
    G02170796Courtesy of MAZDA MOTORS CORP.
  26. Disconnect the following electrical connectors and remove the fuel charging wiring harness from the engine:
    1. Cylinder temperature sensor
    2. Throttle position sensor
    3. Wiring harness to vehicle
    4. Idle air control valve
    5. Camshaft position sensor
    6. Fuel injectors
    Fig 26: Removing Electrical Connectors
    G02170797Courtesy of MAZDA MOTORS CORP.
  27. Disconnect EGR tube fitting.
    Fig 27: Disconnecting EGR Tube Fitting
    G02170798Courtesy of MAZDA MOTORS CORP.
  28. Remove the EGR tube.
    Fig 28: Removing EGR Tube
    G02170799Courtesy of MAZDA MOTORS CORP.
    29. NOTE: The coil is removed from the picture for clarity.
    Fig 29: Removing Coil & Bracket Assembly
    G02170800Courtesy of MAZDA MOTORS CORP.
  29. Remove the coil and bracket assembly.
  30. Remove the thermostat housing.
    • Inspect and install a new O-ring seal if damaged.
    Fig 30: Removing Thermostat Housing
    G02170801Courtesy of MAZDA MOTORS CORP.
  31. Remove the PCV tube.
    Fig 31: Removing PCV Tube
    G02170802Courtesy of MAZDA MOTORS CORP.
    32. NOTE: Illustration shown with throttle body and fuel supply manifold removed for clarity.
    Fig 32: Intake Manifold Bolt Removal Sequence
    G02170803Courtesy of MAZDA MOTORS CORP.
  32. Remove the intake manifold.
    1. Remove the two nuts and five bolts in the sequence shown.
  33. Remove the oil pressure sensor.
    Fig 33: Removing Oil Pressure Sensor
    G02170804Courtesy of MAZDA MOTORS CORP.
  34. Remove the block heater if equipped.
    Fig 34: Removing Block Heater
    G02170805Courtesy of MAZDA MOTORS CORP.
  35. Remove the knock sensor.
    Fig 35: Removing Knock Sensor
    G02170806Courtesy of MAZDA MOTORS CORP.
  36. Remove the oil cooler.
    Fig 36: Removing Oil Cooler
    G02170807Courtesy of MAZDA MOTORS CORP.
  37. Remove the crankshaft sprocket and timing belt guide.
    Fig 37: Removing Crankshaft Sprocket & Timing Belt Guide
    G02170808Courtesy of MAZDA MOTORS CORP.
    38. CAUTION: The bolts are torque-to-yield and new bolts must be installed or engine damage may occur.
    Fig 38: Cylinder Head Bolt Removal Sequence
    G02170809Courtesy of MAZDA MOTORS CORP.
  38. Remove the cylinder head using the sequence shown.
    1. Discard the gasket.
    2. Discard the bolts.
  39. Remove the 17 bolts and the oil pan.
    Fig 39: Removing Oil Pan
    G02170810Courtesy of MAZDA MOTORS CORP.
  40. Remove the bolts and the oil pump cover and screen.
    • Carefully remove and discard the oil pump inlet tube gasket.
    Fig 40: Removing Oil Pump Cover & Screen
    G02170811Courtesy of MAZDA MOTORS CORP.
  41. Remove the lower cylinder block and the gasket.
    Fig 41: Removing Lower Cylinder Block
    G02170812Courtesy of MAZDA MOTORS CORP.
  42. Remove the seven bolts and the oil pump.
    • Remove the oil pump to cylinder block gasket.
    Fig 42: Removing Oil Pump
    G02170813Courtesy of MAZDA MOTORS CORP.
    43. NOTE: Install a new pilot bearing only if it is damaged.
    Fig 43: Removing Pilot Bearing
    G02170814Courtesy of MAZDA MOTORS CORP.
  43. If equipped with a manual transaxle, use the special tool, to remove the pilot bearing.
    1. Install the special tool.
    2. Remove the pilot bearing.
  44. Remove the rear main oil seal retainer assembly and discard the gasket.
    Fig 44: Removing Rear Main Oil Seal Retainer Assembly
    G02170815Courtesy of MAZDA MOTORS CORP.
    45. CAUTION: The connecting rods and connecting rod caps must be correctly oriented, the Interlocking tangs on the same side of the connecting rod or possible engine damage may occur.
    CAUTION: The connecting rod bolts are torque-to-yield. Discard the connecting rod bolts.
    Fig 45: Removing Connecting Rod Caps
    G02170816Courtesy of MAZDA MOTORS CORP.
  45. Remove the four connecting rod caps.
  46. If the connecting rod bearings are to be reused, each one must be identified so that it can be installed in its original location. Remove the four upper and four lower connecting rod bearings.
    Fig 46: Identification Marking Connecting Rod Caps
    G02170817Courtesy of MAZDA MOTORS CORP.
  47. Use a suitable tool and remove the cylinder ridge.
  48. Remove the four piston and connecting rod assemblies.
    Fig 47: Removing Piston & Connecting Rod Assemblies
    G02170818Courtesy of MAZDA MOTORS CORP.
    49. CAUTION: Make sure the main bearing caps are installed in their original position or possible engine damage may occur.
    Fig 48: Removing Crankshaft Main Bearing Caps & Bearings
    G02170819Courtesy of MAZDA MOTORS CORP.
  49. Remove the bolts and remove the crankshaft main bearing caps and bearings.
  50. Remove the crankshaft.
    Fig 49: Removing Crankshaft
    G02170820Courtesy of MAZDA MOTORS CORP.
  51. Remove the upper crankshaft main bearings.
    Fig 50: Removing Upper Crankshaft Main Bearings
    G02170821Courtesy of MAZDA MOTORS CORP.
  52. Remove the Woodruff key.
    Fig 51: Removing Woodruff Key
    G02170822Courtesy of MAZDA MOTORS CORP.
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