2.3L V6: Removal & Installation Mazda Millenia I

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.

Installation

1. Loosen No. 4 engine mount outer bracket bolts and hand tighten. Install engine and transaxle. Install and hand tighten No. 3 engine mount sub-bracket. Install No. 4 engine mount assembly into bracket, hand tight. Tighten No. 4 engine mount lower bolts at chassis to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000) .
2. Remove engine hoist and support engine-transaxle assembly with Engine Support (49 G017 5A0). Install engine mount crossmember to chassis and tighten to specification. Install No. 2 engine mount bolts through engine mount crossmember and hand tighten. Install No. 1 engine mount bracket.
3. Tighten No. 1 engine mount bracket to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000) . Remove engine support. Tighten all remaining engine mounts to specification. Install NEW retaining ring on end of axle shaft. Coat axle shaft splines and sliding surfaces with grease. Install axle shafts in transaxle, with opening of retaining ring facing upward.
4. Pull outward on axle shafts to ensure retaining ring is seated in transaxle. Install and tighten intermediate (joint) shaft support bearing bracket evenly to specification.
5. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000) . Fill engine with oil. Fill A/T transaxle with M-III or Dexron II ATF.
6. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49518-S05192134242001011500000) . Ensure accelerator cable has .06-.16" (1.5-4.0 mm) deflection at throttle body when installed. If deflection is not as specified, rotate nut on end of cable at throttle body until specified deflection is obtained.

Removal

1. Remove negative battery cable. Remove dynamic chamber cover by removing nuts in center of cover, then unsnapping clips along side of cover from front to back. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49518-S27822796592001011500000). Drain cooling system. Remove charge air cooler air duct. Remove air cleaner assembly with air ducts.
2. Remove MAF sensor and air intake hose. Remove air resonator box. Remove left and right charge air coolers. Remove accelerator cable. Remove air intake pipes that connected to charge air cooler assemblies. Remove EGR valve.
3. Remove charge air cooler pipe and fuel inlet hose. (Scheme 19) Remove fuel distributor connector. Remove coolant hose at throttle body and intake manifold. Remove intake manifold assembly.

1. To install reverse removal procedure. Install all intake manifold retaining bolts and nuts before tightening to specification. Tighten all fasteners in sequence to specification. (Scheme 20)
2. Install and tighten all retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000). When installing charge air cooler air intake pipe assembly, hand tighten listed nuts and bolts until air intake pipe No. 3 meets intake manifold. (Scheme 21) Ensure rubber collars are not twisted or distorted. Tighten bolts in sequence. Tighten bolts "A" to 70-95 INCH lbs. (7.9-10.7 N.m). Tighten all other bolts shown to 14-18 ft. lbs. (19-25 N.m).
3. Hand tighten listed nuts and bolts until charge air coolers and air intake pipe No. 1 and No. 2 meet intake manifold. (Scheme 22) Ensure rubber collars are not twisted or distorted. Tighten bolts "A" to 44-78 INCH lbs. (5.0-8.8 N.m). Tighten bolts "B" to 70-95 INCH lbs. (7.9-10.7 N.m). Tighten all other bolts shown to 14-18 ft. lbs. (19-25 N.m).
4. To install remaining components, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49518-S05192134242001011500000). Ensure accelerator cable has.04-.08" (1.0-3.0 mm) free play at throttle body when installed. If free play is not as specified, rotate nut on end of cable at throttle body until specified free play is obtained.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold heat insulator. Remove retaining bolts, nuts, exhaust manifold and gasket.
2. To install, reverse removal procedure using NEW exhaust manifold gasket. Tighten bolts and nuts in sequence to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000). (Scheme 23)

Scheme 23

1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-49518-S01181517032001011500000). Remove front header pipe and right exhaust manifold. See «EXHAUST MANIFOLD»(ref-49518-S02692257912001011500000). Remove throttle body assembly from Lysholm compressor. (Scheme 19) Remove drive belt and Lysholm compressor.
2. Remove timing belt. See «TIMING BELT»(ref-49518-S35943676962001011500000). Remove spacer at front of left cylinder head. Remove all ignition coils. (Scheme 23) Remove valve covers.
3. Remove camshaft pulleys while holding camshafts with wrench on cast hexagon area of camshaft. Remove camshafts. See CAMSHAFT. Remove lower radiator hose. Remove water inlet pipe.
4. Remove Lysholm compressor bracket. Remove generator bolt. Remove left cylinder head rubber insulator. CAUTION: Cylinder head bolts must be loosened in proper sequence to prevent cylinder head warpage. (Scheme 24)
5. Loosen cylinder head bolts in sequence using several steps. (Scheme 24) Remove cylinder head bolts and washers, cylinder heads and gaskets.

Scheme 24

1. Disconnect negative battery cable. Remove timing belt. See «TIMING BELT»(ref-49518-S35943676962001011500000) . Using puller, remove crankshaft sprocket. Remove woodruff key from crankshaft. Using a knife, cut seal lip from seal. Pry seal from oil pump body. DO NOT damage sealing surfaces.
2. To install, apply engine oil to seal lip of NEW seal. Install seal on crankshaft. Using hammer and pipe of suitable diameter, tap seal into oil pump body until seal surface is even with oil pump body. To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Remove transaxle and flexplate. For transaxle removal procedure, see appropriate article in the TRANSMISSION SERVICING section. Pry out oil seal.
2. To install, apply light coat of oil to seal lip and push seal over crankshaft. Tap seal into rear cover until it is flush with edge of rear cover. DO NOT bottom seal in cover.
3. Completely remove used sealant from flexplate bolts. Apply lock-type sealant to bolts, and install flexplate to crankshaft. Tighten flexplate bolts to 45-49 ft. lbs. (61-67 N.m) in a crisscross pattern. Install transaxle.

1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove components in order indicated in illustration.
4. Install in reverse order of removal. See «Installation Note»(ref-49518-S32382712142010051400000)
5. Start engine and check for coolant leaks.

Scheme 25

Installation Note

Install the thermostat into the thermostat cover with the jiggle pin and projection aligned.

Scheme 26

Disconnect negative battery cable. Drain cooling system. Remove engine mount bracket located above water pump on cylinder block. Remove timing belt and water pump together. See TIMING BELT . Remove retaining bolts, water pump and seal ring.

To install, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove lower engine covers. Remove front exhaust pipe.
2. Remove oil pan retaining bolts. Install a screwdriver or seal cutter between cylinder block and oil pan. Slightly pry apart to separate oil pan from cylinder block. Remove oil pan. Remove retaining bolts, pick-up tube and gasket (if necessary).

1. Install gasket and pick-up tube (if removed). Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000) . Ensure sealing surfaces are clean. Apply bead of sealant on inside of bolt holes and at center of oil pan sealing surface, between bolt holes. CAUTION: Before installing oil pan bolts, ensure oil pan bolts and cylinder block bolt holes are free of sealant. Cylinder block may be crack if bolts are not cleaned before installation.
2. Install oil pan. Install bolts, and tighten them to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000) . To install remaining components, reverse removal procedure. Fill crankcase with oil.

Scheme 27

1. Inspect cylinder head warpage at cylinder block and manifold areas. Resurface or replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-49518-S01424873092001011500000) under ENGINE SPECIFICATIONS. CAUTION: Ensure cylinder head height is within specification after resurfacing cylinder head. See «CYLINDER HEAD»(ref-49518-S01424873092001011500000) under ENGINE SPECIFICATIONS. (Scheme 27)
2. Ensure valve stem installed height is within specification. See VALVES under «CYLINDER HEAD»(ref-49518-S01424873092001011500000). Ensure cylinder head-to-tappet oil clearance is within specification. See «TAPPET»(ref-49518-S14159004052001011500000) under ENGINE SPECIFICATIONS.

Removal & Disassembly

Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump pick-up tube and baffle plate. Remove retaining bolts, oil pump and "O" ring. Remove oil pump body cover and oil pump components. (Scheme 28)

Scheme 28

Reassembly & Installation

1. To reassemble, coat rotors with engine oil. Install rotors in oil pump body. Ensure reference marks (dots) on rotors face outside of oil pump body (toward oil pump cover) and are aligned at top of oil pump body.
2. Install oil pump body cover, and tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000). Install relief valve, spring, NEW gasket and relief valve plug. Tighten relief valve plug to specification.
3. Install crankshaft front seal (if removed) until seal surface is even with oil pump body. Coat seal lip with grease. To install, apply sealant on rear of oil pump. Coat NEW "O" ring with oil and install on rear of oil pump. Install oil pump. Ensure splined teeth on rotor of oil pump engages with splines on crankshaft.
4. Install proper length bolts in designated locations. (Scheme 29) Tighten retaining bolts to specification. Install baffle plate and retaining bolts. Tighten bolts to specification. Install gasket and pick-up tube. Tighten pick-up tube-to-oil pump bolts to specification, then pick-up tube support bracket bolts. To install remaining components, reverse removal procedure.

Scheme 29

1. Disconnect negative battery cable. Drain cooling system. Disconnect coolant hoses from oil cooler. Remove oil filter and remove retaining nut from filter adapter. Remove oil cooler and "O" ring from oil filter bracket.
2. To install, reverse removal procedure using NEW "O" ring coated with engine oil. Tighten retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000) . Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49518-S05192134242001011500000) under REMOVAL & INSTALLATION.

1. With crankshaft and main bearings removed, remove oil jet from cylinder block main bearing bore. (Scheme 30)
2. Ensure threads on oil jet and cylinder block are clean. Apply thread sealant on oil jet threads. Install oil jet and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-49518-S02538651592001011500000).

Scheme 30