2.0L 4-Cylinder: Removal & Installation Mazda 626 GF

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal

1. Release residual pressure from fuel system. See «FUEL PRESSURE RELEASE & PRIMING»(ref-3925-S38840176532000052600000). Disconnect negative battery cable. Drain cooling system and transaxle. Remove engine undercover. Remove air intake ducting and air cleaner assembly.
2. Remove battery and tray. Disconnect accelerator cable. Remove fuel filter and radiator hoses. Remove radiator and cooling fan assembly. Remove power steering pump and A/C compressor with hoses attached, and support aside.
3. Disconnect necessary electrical connectors, hoses and cables. Remove cruise control actuator. Remove axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES.
4. Remove nuts securing engine mounts to engine mount member (large support piece that runs from front to rear, under flywheel/drive plate end of engine). Support engine from above using hoist. Support engine mount member from below. Remove bolts and nuts securing engine mount member to body. Remove engine mount member.
5. Remove exhaust pipe under engine. On M/T, remove shift control rod and extension (support) bar. On all models, disconnect stabilizer bar and tie rod ends. Separate ball joints from steering knuckles.
6. Remove engine mount No. 1 stay bracket. (Scheme 2) Remove No. 3 engine mount. Remove No. 1 engine mount bolts. Remove No. 4 engine mount and bracket. Remove engine and transaxle assembly.

Installation

To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS . Use NEW cotter pin on tie rod ends. Fill all fluids to correct level. Prime fuel system before attempting to start engine. See FUEL PRESSURE RELEASE & PRIMING . Bleed cooling system. See COOLING SYSTEM BLEEDING .

Scheme 2

Release residual pressure from fuel system. See FUEL PRESSURE RELEASE & PRIMING . Disconnect negative battery cable. Drain cooling system. Remove air intake ducting and air cleaner assembly. Disconnect accelerator cable. Disconnect necessary electrical connectors, hoses and cables. Remove throttle body assembly and fuel rail assembly. Remove intake manifold bracket, bolts and intake manifold.

To install, reverse removal procedure. Tighten intake manifold bolts to specification. See TORQUE SPECIFICATIONS . Prime fuel system before attempting to start engine. See FUEL PRESSURE RELEASE & PRIMING . Bleed cooling system. See COOLING SYSTEM BLEEDING .

Disconnect necessary electrical connectors, hoses and cables. Remove exhaust manifold shield. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold bolts and nuts. Remove exhaust manifold. To install, reverse removal procedure. Tighten exhaust manifold bolts to specification. See TORQUE SPECIFICATIONS .

1. Release residual pressure from fuel system. See «FUEL PRESSURE RELEASE & PRIMING»(ref-3925-S38840176532000052600000). Disconnect negative battery cable. Drain cooling system. Remove engine undercover. Remove air intake ducting and air cleaner assembly. Disconnect necessary electrical connectors, fuel hoses and control cables. Remove ignition coil. CAUTION: To prevent cylinder head warpage or cracking, loosen cylinder head bolts in proper sequence. (Scheme 4)
2. Remove upper radiator hose, by-pass hose and heater hoses. Remove timing belt. See «TIMING BELT»(ref-3925-S31856660452000052600000). Remove camshafts. See «CAMSHAFTS»(ref-3925-S01136233982000052600000). Remove intake manifold bracket. Loosen cylinder head bolts in 2-3 steps, in proper sequence. (Scheme 4) Remove cylinder head bolts. Remove cylinder head and gasket.

1. Install NEW cylinder head gasket. Install cylinder head. Apply oil to bolt threads and bolt seating surface. Tighten cylinder head bolts to specification in 2-3 steps, in proper sequence. (Scheme 5) See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000).
2. To install remaining components, reverse removal procedure. Before installing valve cover, apply silicone sealant to seams where front camshaft bearing caps contact cylinder head. Install NEW valve cover gasket in valve cover.
3. Tighten valve cover bolts to specification in 5-6 steps, in proper sequence. (Scheme 3) See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000). Prime fuel system before attempting to start engine. See «FUEL PRESSURE RELEASE & PRIMING»(ref-3925-S38840176532000052600000). Bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3925-S36414367512000052600000).

Scheme 3

Scheme 4

Scheme 5

Remove timing belt. See TIMING BELT . Remove timing belt pulley and key. Cut oil seal with knife. Using screwdriver protected with a rag, pry oil seal from front cover. To install, apply oil to sealing lip of new oil seal. Tap oil seal into bore until seal is even with face of oil pump body. To install remaining components, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable. Remove timing belt. See TIMING BELT. Remove camshaft sprockets (hold hex portion of camshaft to remove bolt). (Scheme 7) Loosen camshaft bearing cap bolts in several steps, starting at ends and working inward. Remove bearing caps and camshafts. Remove camshaft oil seals.

1. Apply oil to camshaft friction surfaces. Install camshafts with dowel pin facing upward. Apply silicone sealant to surfaces of cylinder head where camshaft front bearing caps contact cylinder head. DO NOT allow sealant to contact journal surfaces.
2. Intake camshaft bearing caps are numbered 1-5 from front to rear. Exhaust camshaft bearing caps are numbered 6-10 from front to rear. Install camshaft bearing caps, tightening bolts to specification in 5-6 steps, starting at center and working outward. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000).
3. Apply oil to NEW camshaft oil seals. Install seals until even with face of bearing cap. Install camshaft sprockets, ensuring timing marks are aligned. (Scheme 6)

Scheme 6

Scheme 7

Drain engine oil. Remove transmission and flywheel/drive plate. On A/T, see TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. On M/T, see appropriate article in CLUTCHES. Remove flywheel or flexplate. On all models, cut oil seal with knife. Using screwdriver protected with a rag, pry oil seal from rear cover. Remove rear cover bolts and rear cover (if necessary).

1. If rear cover was not removed, go to next step. If rear cover was removed, clean old sealant from sealing surfaces of rear cover and cylinder block. Apply continuous bead of silicone sealant to sealing surface of rear cover, running sealant bead inside bolt holes. Install rear cover. Tighten rear cover bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000) .
2. Apply oil to sealing lip of new oil seal. Tap oil seal into bore until seal is even with face of rear cover. To install remaining components, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000) .

Note. Numbers in parenthesis refer to numbers in illustration.

1. Disconnect the negative battery cable. Drain the engine coolant. Remove lower radiator hose (1). (Scheme 8) Remove thermostat housing (2). Remove thermostat (3).
2. To install, reverse removal procedure. Verify that the jiggle pin is aligned with the projection of the thermostat gasket as shown. (Scheme 9) Install the thermostat into the thermostat case, aligning the projection on the gasket to the thermostat case as shown. (Scheme 10)
3. Tighten thermostat housing bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000).

Scheme 8

Scheme 9

Scheme 10

Removal & Installation (1999)

1. Disconnect the negative battery cable. Drain the engine coolant. Remove the fresh air duct. Remove electric cooling fan assembly (1). Remove the oil pipe (A/T). Remove radiator (2). (Scheme 11)
2. To install, reverse removal procedure. When tightening electric cooling fan assembly to radiator, tighten the 2 bolts on the left side first, then the remaining bolt on the right top. (Scheme 11) Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3925-S36414367512000052600000).

Scheme 11

Removal & Installation (2000)

1. Disconnect the negative battery cable. Drain the engine coolant. Remove the fresh air duct. Remove the oil pipe (A/T). Remove radiator (1). (Scheme 12) Remove electric cooling fans (2) from radiator, if necessary.
2. To install, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3925-S36414367512000052600000).

Scheme 12

Disconnect negative battery cable. Drain coolant. Remove timing belt. See TIMING BELT . Remove water pump. To install, reverse removal procedure. Use NEW water pump gasket. Bleed cooling system. See COOLING SYSTEM BLEEDING .

1. Disconnect negative battery cable. Remove engine undercover. Drain engine oil. Disconnect oxygen sensor connector. Remove front exhaust pipe. Remove oil pan bolts.
2. Note weld nut on right flange of oil pan. Screw oil pan bolt into weld nut to create a small gap between oil pan and oil pan upper block. Separate oil pan from oil pan upper block using a screwdriver. DO NOT damage sealing surfaces. Remove oil pan. (Scheme 13) Remove oil strainer (if necessary).

1. Install oil strainer and NEW gasket (if removed). Tighten oil strainer bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000) . If reusing old oil pan bolts, remove old sealant from bolt threads.
2. Clean old sealant from sealing surfaces of oil pan and oil pan upper block. Apply continuous bead of silicone sealant to oil pan flange, running sealant bead inside bolt holes. Install oil pan within 5 minutes of applying sealant. Tighten oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000) . Fill engine with oil to specification. See «ENGINE LUBRICATION SYSTEM»(ref-3925-S01961086242000052600000) under ENGINE OILING.

Remove oil pan. See OIL PAN. Remove 2 nuts from rear end of cylinder block. Loosen oil pan upper block bolts in 2-3 steps, in proper sequence. (Scheme 14) Separate oil pan upper block from cylinder block using screwdriver at rear corner, being careful not to damage sealing surfaces. Remove oil pan upper block.

1. Clean old sealant from sealing surfaces of oil pan upper block and cylinder block. Apply continuous bead of silicone sealant to oil pan upper block, running sealant bead inside bolt holes. Install oil pan upper block within 5 minutes of applying sealant.
2. At rear end of cylinder block, tighten 2 nuts to specification. Tighten oil pan upper block bolts to specification in 2-3 steps, in proper sequence. (Scheme 15) See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000). To install remaining components, reverse removal procedure.

Scheme 13

Scheme 14

Scheme 15

Removal & Disassembly

1. Disconnect negative battery cable. Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-3925-S31856660452000052600000) under REMOVAL & INSTALLATION. Remove front cover bolts and front cover. Using a screwdriver protected with a rag, drive oil seal out from inside of front cover.
2. Remove pump cover screws (use a manual impact screwdriver, if necessary). (Scheme 16) Remove pump cover. Note location of alignment marks on inner and outer rotors. Remove inner and outer rotors. To remove pressure relief valve, remove snap ring, spring seat, pressure spring and control plunger.

Reassembly & Installation

1. Apply oil to friction surfaces. Install inner and outer rotors with marks aligned. (Scheme 17) Install pressure relief valve components. Apply oil to lip of NEW oil seal. Press oil seal into bore until even with face of front cover. Install pump cover. Tighten screws to 53-78 INCH lbs. (6-9 N.m).
2. Apply silicone sealant to front cover sealing surface, running silicone bead inside bolt holes. Install front cover. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3925-S00350375562000052600000). To complete installation, reverse removal procedure.

OIL PUMP SPECIFICATIONS

Scheme 16

Scheme 17