2.3L V6: Removal & Installation Mazda Millenia I facelift

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 fuel pressure. See «FUEL PRESSURE RELEASE»(ref-3917-S36820705292000052500000). Disconnect negative battery cable. Drain cooling system, engine oil and transaxle fluid. Reference mark hood hinges and remove hood. Raise and support vehicle. Remove front wheels.
2. Remove dynamic chamber cover by removing nuts in center of cover, then unsnapping clips along side of cover from front to back. Remove lower engine covers. Remove air intake duct and air cleaner assembly. Remove battery and battery tray. Disconnect necessary control cables, electrical connections, coolant hoses, vacuum hoses and fuel lines. Remove drive belt, crankshaft pulley and vacuum pump pulley. Vacuum pump pulley has left hand threads. Remove A/C compressor, leaving hoses attached and wire aside. Remove power steering pump, leaving hoses attached, and wire aside.
3. Remove front grill, radiator cover and coolant reservoir. Disconnect electrical connectors from electric cooling fans. Remove radiator and condenser fan assemblies. Remove transmission cooler lines from radiator.
4. Remove upper and lower hose at radiator. Remove radiator retaining bolts from bracket at bottom corners of radiator. Remove radiator assembly. Disconnect heater hoses at bulkhead.
5. Remove accelerator cable and drive belt. Remove A/C compressor and power steering oil pump with hoses still connected. Position compressor and oil pump away from engine, and hold with wire.
6. Remove selector cable and front exhaust pipe. Using ball joint separator, remove upper lateral ball joint. Separate lower ball joints. Using bar inserted between axle shaft and transaxle, pry axle shafts from transaxle. DO NOT damage oil seal when removing axle shaft. Remove drive shaft and intermediate (joint) shaft.
7. Support engine with hoist. Remove No. 1 engine mount bracket. (Scheme 16) Remove engine mount crossmember. Using engine hoist, remove weight from No. 3 and 4 engine mounts. Remove No. 4 engine mount assembly. Remove No. 3 engine mount sub-bracket. Lift engine and transaxle from vehicle.

Scheme 16

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 bolts. 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-3917-S38585952592000052500000) .
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 bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000) . 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-3917-S38585952592000052500000) . 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-3917-S40966717562000052500000) . 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.

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-3917-S36820705292000052500000). 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 connect to charge air cooler assemblies. Remove EGR valve.
3. Remove charge air cooler pipe and fuel inlet hose. (Scheme 17) 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 18)
2. Install and tighten all retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000). 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 19) 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 20) 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-3917-S40966717562000052500000). 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 17

Scheme 18

Scheme 19

Scheme 20

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-3917-S38585952592000052500000). (Scheme 21)

Scheme 21

1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-3917-S18799569532000052500000). Remove front header pipe and right exhaust manifold. See «EXHAUST MANIFOLD»(ref-3917-S37688226212000052500000). Remove throttle body assembly from Lysholm compressor. (Scheme 17) Remove drive belt and Lysholm compressor.
2. Remove timing belt. See «TIMING BELT»(ref-3917-S12728635242000052500000). Remove spacer at front of left cylinder head. Remove all ignition coils. Remove valve covers.
3. Remove camshaft pulleys while holding camshafts with wrench on cast hexagon area of camshaft. Remove camshafts. See «CAMSHAFT»(ref-3917-S06559165192000052500000). Remove lower radiator hose. Remove water inlet pipe.
4. Remove Lysholm compressor bracket. Remove generator bolt. Remove left cylinder head rubber insulator. CAUTION: Loosen cylinder head bolts in proper sequence to prevent cylinder head warpage. (Scheme 22)
5. Loosen cylinder head bolts in sequence using several steps. (Scheme 22) Remove cylinder head bolts and washers, cylinder heads and gaskets.

Scheme 22

1. Disconnect negative battery cable. Remove timing belt. See «TIMING BELT»(ref-3917-S12728635242000052500000) . 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. Drain coolant. Raise and support vehicle. Remove right front wheel. Remove lower engine covers. Remove accessory drive belts.
2. Remove crankshaft pulley retaining bolt. Using puller, remove crankshaft pulley. Remove power steering pump pulley. Remove water pump pulley. Remove generator drive belt auto tensioner. (Scheme 23) Remove camshaft position sensor from right hand camshaft.
3. Remove engine oil dipstick and pipe. Remove vacuum pipe. Remove upper radiator hose. Support engine using hoist. Remove No. 3 engine mount and brackets from timing belt end of engine. Remove retaining bolts, timing belt covers and gaskets. Remove power steering belt auto tensioner. (Scheme 23)
4. Install crankshaft pulley retaining bolt in crankshaft. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. The crankshaft and camshaft timing marks should align. (Scheme 24)
5. If reusing timing belt, place reference mark on timing belt to indicate direction of rotation. Hold timing belt tensioner and remove lower retaining bolt first, then remove upper bolt. Remove timing belt tensioner. Remove timing belt.

Scheme 23

Scheme 24

1. Place timing belt auto tensioner in a press using a flat washer to prevent damage to timing belt tensioner. (Scheme 25) Using no more than 2200 lbs. of pressure, compress tensioner rod until holes in rod and housing are aligned. Install a.055-.063" (1.4-1.6 mm) diameter pin through holes in housing and rod to hold rod in retracted position. (Scheme 25)
2. Install timing belt on sprockets and around idler pulleys in the sequence shown. (Scheme 26) Ensure all slack is on tensioner pulley side. Install timing belt auto tensioner. Tighten timing belt auto tensioner bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000). Ensure all timing marks align. (Scheme 24)
3. Remove pin from timing belt tensioner, allowing tension to be applied on timing belt. Rotate crankshaft 2 full revolutions clockwise from TDC to TDC. Ensure timing marks on camshaft sprockets and crankshaft sprockets are properly aligned. (Scheme 24) If timing marks are not aligned, remove and repeat entire timing belt installation procedure.
4. Install timing belt covers using NEW gaskets. Tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000). Install dipstick tube with new "O" ring.
5. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000). Check ignition timing. Adjust drive belts to proper tension.

Scheme 25

Scheme 26

1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-3917-S18799569532000052500000). Remove front header pipe and right exhaust manifold. See «EXHAUST MANIFOLD»(ref-3917-S37688226212000052500000). Remove timing belt. See «TIMING BELT»(ref-3917-S12728635242000052500000). Remove spacer at front of left cylinder head. Remove ignition coils. Remove valve covers.
2. Remove camshaft pulleys while holding camshafts with wrench on cast hexagon area of camshaft. Rotate camshafts clockwise until camshaft lobes are not contacting adjustment shims. Loosen front camshaft cap bolts in sequence in 5-6 steps. (Scheme 27) Remove front camshaft caps.
3. Note location of remaining camshaft bearing caps for reassembly reference. Camshaft bearing caps on right cylinder head are numbered for location with No. 1 at timing belt end of engine. (Scheme 28) Camshaft bearing caps on left cylinder head contain letters for location with "A" at timing belt end of engine.
4. Loosen remaining camshaft bearing cap bolts, in sequence, using several steps. Remove all camshaft bearing caps except thrust bearing cap. Thrust bearing caps are removed last. Thrust bearing caps are identified with No. 4 and No. 8 on right cylinder head and "A" and "E" on left cylinder head.

Scheme 27

Scheme 28

1. Disconnect negative battery cable. Remove transaxle and flexplate. For transaxle removal procedure, see TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. 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 in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000) . Install transaxle.

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 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-3917-S22763244952010051400000)
5. Start engine and check for coolant leaks.

Scheme 29

Installation Note

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

Scheme 30

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-3917-S38585952592000052500000) . 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 crack if bolts are not cleaned before installation.
2. Install oil pan. Install bolts, and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000) . To install remaining components, reverse removal procedure. Fill crankcase with oil.

Scheme 31

1. Inspect cylinder head warpage at cylinder block and manifold areas. Resurface or replace cylinder head if warpage exceeds specification. See «CYLINDER HEAD»(ref-3917-S31334376842000052500000) table under ENGINE SPECIFICATIONS. CAUTION: Ensure cylinder head height is within specification after resurfacing cylinder head. See «CYLINDER HEAD»(ref-3917-S31334376842000052500000) table under ENGINE SPECIFICATIONS. (Scheme 31)
2. Ensure valve stem installed height is within specification. See «VALVES»(ref-3917-S40015800582000052500000). Ensure cylinder head-to-tappet oil clearance is within specification. See «TAPPET»(ref-3917-S13058546432000052500000) table 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 32)

Scheme 32

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-3917-S38585952592000052500000). 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 33) Install baffle plate and retaining bolts. Tighten retaining bolts to specification. Install gasket and pick-up tube. To install remaining components, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000).

Scheme 33

1. Disconnect negative battery cable. Drain cooling system. Disconnect coolant hoses from oil cooler. Remove oil filter and cooler hose. Remove insulator. Remove oil cooler.
2. To install, reverse removal procedure. Tighten retaining nut to specification. See «TORQUE SPECIFICATIONS»(ref-3917-S38585952592000052500000) . Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-3917-S40966717562000052500000) under REMOVAL & INSTALLATION.

1. With crankshaft and main bearings removed, remove oil jet from cylinder block main bearing bore. (Scheme 34)
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-3917-S38585952592000052500000).

Scheme 34