3.0L V6: Removal & Installation Mazda MPV 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.

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49061-S41722374142001011500000) under REMOVAL & INSTALLATION. Remove hood, battery and starter. Raise and support vehicle. Remove transmission.
2. Drain cooling system and engine oil. Remove air intake duct located above radiator. Remove lower engine cover. Disconnect radiator hoses from radiator. Remove cooling fan and fan shroud. Disconnect transmission oil cooler lines at transmission (if equipped). Remove radiator.
3. Remove drive belts and air cleaner assembly. Disconnect necessary control cables, electrical connections and vacuum hoses. Cover fuel line connections with shop towel to absorb residual fuel in lines. Disconnect fuel lines.
4. Remove alternator. Using Pulley Holder (49-W023-585A), hold power steering pump pulley. Remove retaining nut and power steering pump pulley. Remove power steering pump and A/C compressor with hoses attached, and secure aside (if equipped).
5. Remove plastic protective cover from top right front of engine. Disconnect engine wiring harness and ground wires. Remove A/C hose bracket from center of firewall. Remove shroud upper panel from right side of firewall. Disconnect exhaust pipe.
6. Remove lower grille and radiator grille. Remove radiator fan shroud upper plate. This is plate which fan shroud bolts to, located above radiator area. Remove retaining nut securing engine mount bracket on cylinder block to engine mount. Remove engine.

Installation

1. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) . Fill engine with oil.
2. Before installing radiator fan shroud upper plate, apply sealant at each end where plate contacts bracket on body. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49061-S07936271982001011500000) under REMOVAL & INSTALLATION.
3. Ensure accelerator cable has .04-.12" (1.0-3.0 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. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49061-S41722374142001011500000). Disconnect negative battery cable. Drain cooling system. Remove fresh air duct, air cleaner and air intake tube. Disconnect accelerator cable.
2. Disconnect necessary electrical connectors, control cables, coolant hoses and vacuum hoses. Cover fuel line connections with shop towel to absorb residual fuel in line. Disconnect fuel lines. Remove intake air pipe and gasket. (Scheme 17)
3. Remove extension manifolds, gaskets and "O" rings. Remove retaining nuts, delivery pipe with fuel injectors and insulators. (Scheme 17) CAUTION: DO NOT allow fuel injectors to fall from delivery pipe during removal.
4. Loosen intake manifold retaining nuts in 2 steps using proper sequence. (Scheme 18) Remove retaining nuts, washers, intake manifold and gaskets.

1. Install NEW gaskets on cylinder heads. Install intake manifold. Install washers with White paint mark upward (away from intake manifold).
2. Install and tighten retaining nuts to specification in 2 steps using proper sequence. (Scheme 18) See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
3. If installing fuel injectors on delivery pipe, install NEW "O" ring on fuel injector. Coat "O" ring with engine oil. Install fuel injector on delivery pipe.
4. Install insulators, fuel injectors, spacers and delivery pipe on intake manifold. Install and tighten delivery pipe retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
5. Install NEW "O" ring on intake manifold. The "O" ring fits between intake manifold and dynamic chamber, near stud area. (Scheme 17) CAUTION: Ensure "O" ring is installed on intake manifold before installing dynamic chamber.
6. Install dynamic chamber. Install and tighten retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
7. Install extension manifolds using NEW "O" rings and gaskets. Tighten retaining nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
8. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49061-S07936271982001011500000) under REMOVAL & INSTALLATION.
9. Ensure accelerator cable has.04-.12" (1.0-3.0 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.

Scheme 17

Scheme 18

1. Disconnect exhaust pipe from exhaust manifold. Disconnect oxygen sensor connector (if necessary). Remove heat shield and crossover pipe. Remove exhaust manifold heat shields and exhaust manifolds.
2. To install, reverse removal procedure using NEW gaskets. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) .

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49061-S41722374142001011500000). Disconnect negative battery cable. Drain cooling system. Remove air intake hose. Disconnect accelerator cable from throttle body. Remove spark plug cables and spark plugs.
2. Remove timing belt. See «TIMING BELT»(ref-49061-S22953290602001011500000) under REMOVAL & INSTALLATION. Remove intake manifold. See «INTAKE MANIFOLD»(ref-49061-S36232874032001011500000) under REMOVAL & INSTALLATION. Remove exhaust manifold. See «EXHAUST MANIFOLD»(ref-49061-S17708180702001011500000) under REMOVAL & INSTALLATION.
3. Remove distributor. Remove retaining bolts, valve cover and gasket. Remove seal plate, bolted to front of cylinder head. Loosen cylinder head bolts in sequence, using 3 steps. (Scheme 19) Remove cylinder head bolts, cylinder head and gasket.

Scheme 19

1. Ensure oil control plugs are installed in cylinder block. (Scheme 20) Measure oil control plug protrusion from top of oil control plug-to-cylinder block deck surface. Oil control plug protrusion should be.209-.224" (5.30-5.70 mm).
2. Coat NEW "O" rings with engine oil and install on oil control plug. Install cylinder head gasket on cylinder block. CAUTION: Cylinder head gaskets are marked "L" identification mark for left bank and "R" identification mark for right bank. Gaskets must be installed in proper location. Identification mark must face upward (away from cylinder block). Reference to right and left bank is viewed from rear of engine.
3. Ensure oil control plug "O" rings are coated with engine oil. Install cylinder head. Apply engine oil on cylinder head bolt threads and cylinder head bolt-to-cylinder head contact surfaces.
4. Install and tighten cylinder head bolts to specification in sequence. (Scheme 19) See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
5. Install valve cover using NEW seal washers on retaining bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
6. When installing distributor, rotate crankshaft so cylinder No. 1 is at TDC on compression stroke. NOTE: Cylinder No. 1 is front cylinder on right side when viewed from rear of engine.
7. Ensure timing mark on crankshaft pulley aligns with TDC mark on timing belt cover. Position distributor rotor so it aligns with spark plug wire for No. 1 cylinder.
8. Install distributor and hold-down bolt. To install remaining components, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000). Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49061-S07936271982001011500000) under REMOVAL & INSTALLATION. Adjust ignition timing.

Scheme 20

1. Remove oil pump. See «OIL PUMP»(ref-49061-S16718668582001011500000) under ENGINE OILING. Using hammer and punch, tap seal from oil pump body. Use care not to damage sealing surfaces.
2. To install, apply engine oil to seal lip of NEW seal. Using hammer and suitable diameter pipe, tap seal into oil pump body until seal surface is even with oil pump body.

Scheme 21

1. Disconnect negative battery cable. Drain cooling system. Remove spark plug wires and spark plugs. Remove air intake hose. Remove cooling fan and fan shroud.
2. Remove drive belts. Remove A/C compressor drive belt idler pulley. Remove retaining bolt and crankshaft pulley. Remove coolant by-pass and upper radiator hoses. Remove timing belt covers and gaskets. (Scheme 21) Rotate crankshaft and align all timing marks. (Scheme 22)
3. If reusing timing belt, place reference mark on timing belt to indicate direction of timing belt rotation. Remove upper idler pulley. (Scheme 21) Remove timing belt. Remove timing belt tensioner, tensioner pulley and lower idler pulley (if necessary).
4. If removing camshaft sprocket, hold camshaft using Sprocket Holder (SST-49-H012-010) on front of camshaft sprocket. Remove retaining bolt and camshaft sprocket.
5. If removing crankshaft sprocket, use puller to remove crankshaft sprocket from crankshaft. Remove key from crankshaft (if necessary).

Scheme 22

1. Remove retaining bolts, seal washers, valve cover and gasket. Loosen rocker shaft bolts in sequence using 3 steps. (Scheme 23)
2. Remove rocker arm and shaft assemblies with retaining bolts. Remove valve lash adjuster from rocker arm (if necessary) by hand or using pliers covered with shop towel.

Note. DO NOT remove valve lash adjuster unless necessary, as "O" ring may be damaged during removal.

1. Install NEW "O" ring on valve lash adjuster (if removed). Coat rocker arm oil reservoir and valve lash adjuster with engine oil.
2. Install valve lash adjuster in rocker arm, ensuring "O" ring is not damaged. Apply engine oil to bearing surface of rocker arms and shaft. Install rocker arm and shaft assemblies.
3. Install rocker arm shaft bolts, and tighten to specification in sequence using 3 steps. (Scheme 23) See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000). Install valve cover, using NEW seal washers on retaining bolts.

Scheme 23

1. Remove timing belt and camshaft sprockets. See «TIMING BELT»(ref-49061-S22953290602001011500000) under REMOVAL & INSTALLATION. Remove distributor (if necessary).
2. Remove retaining bolts, seal washers, valve cover and gasket. Loosen rocker shaft bolts in sequence using 3 steps. (Scheme 23) Remove rocker arm and shaft assemblies with retaining bolts. Remove camshaft oil seals from front of camshaft.
3. Using dial indicator, check camshaft end play. Replace camshaft thrust plate or camshaft if end play is not within specification. See «CAMSHAFT SPECIFICATIONS»(ref-49061-S31073454452001011500000) table under ENGINE SPECIFICATIONS.
4. Remove retaining bolts and camshaft thrust plate, located at rear of cylinder head, near rocker arm shaft bolts. Remove camshaft.

1. Coat camshaft and camshaft bores in cylinder head with engine oil. Install camshaft in cylinder head.
2. Install camshaft thrust plate. Install and tighten camshaft thrust plate bolt to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
3. Apply engine oil to bearing surface of rocker arms and shaft. Install rocker arm and shaft assemblies. Install and tighten rocker arm shaft bolts to specification in sequence using 3 steps. (Scheme 23) See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000).
4. When installing distributor, rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. NOTE: The No. 1 cylinder is front cylinder on right side when viewed from rear of engine.
5. Ensure timing mark on crankshaft pulley aligns with TDC mark on timing belt cover. Position distributor rotor so it aligns with spark plug wire for No. 1 cylinder.
6. Install distributor and hold-down bolt. To install remaining components, reverse removal procedure. Ensure NEW seal washers are used on valve cover retaining bolts. Adjust ignition timing.

Disconnect negative battery cable. Drain engine oil. Remove transmission, clutch assembly (if equipped), and flywheel or drive plate. Pry oil seal from rear seal housing on rear of cylinder block. DO NOT damage sealing surfaces.

1. Ensure all sealing surfaces are clean. Apply engine oil to lip of NEW oil seal. Place oil seal on crankshaft. Using hammer and suitable diameter pipe, install oil seal in rear seal housing until oil seal is even with rear seal housing surface.
2. Install flywheel or drive plate. Tighten flywheel or drive plate bolts to specification in a crisscross pattern. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) . To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Rotate crankshaft so No. 1 cylinder is at TDC on compression stroke. NOTE: The No. 1 cylinder is front cylinder on right side when viewed from rear of engine.
2. Drain cooling system. Remove timing belt. See «TIMING BELT»(ref-49061-S22953290602001011500000) . Remove idler pulleys for timing belt (if necessary). Remove retaining bolts, nuts, water pump and gasket.
3. To install, reverse removal procedure using NEW gasket. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) . Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-49061-S07936271982001011500000) under REMOVAL & INSTALLATION.

1. Disconnect negative battery cable. Raise and support vehicle. Drain engine oil. Remove lower engine covers.
2. On 2WD models, remove transmission-to-cylinder block support braces, located at rear corners of oil pan.
3. On 4WD models, remove air intake duct located above radiator. Remove cooling fan and fan shroud. Support engine with hoist. Support transmission with floor jack.
4. Remove retaining nuts securing engine mount brackets on cylinder block to engine mounts. Slightly raise engine. CAUTION: DO NOT remove engine mount-to-frame nuts. Remove only upper nuts, retaining engine mount bracket on cylinder block to engine mount.
5. Remove transmission crossmember located below front of transmission. Disconnect automatic transmission oil cooler hose (if equipped). Remove stabilizer bar-to-frame clamp bolts.
6. On all models, remove oil pan retaining bolts. Insert gasket scraper between oil pan and cylinder block and separate oil pan from cylinder block. Remove oil pan and gasket (if used).

1. Ensure sealing surfaces are clean. Apply sealant on cylinder block at oil pump body-to-cylinder block and rear seal housing-to-cylinder block surfaces.
2. Install gasket (if used). If gasket is not used, apply sealant on oil pan. Ensure sealant is applied on inside of bolt holes on oil pan. Install oil pan. Install and tighten retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) .
3. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) . Fill engine with oil.

Removal & Disassembly

1. Remove engine. See ENGINE under «REMOVAL & INSTALLATION»(ref-49061-S33497050002001011500000). Remove timing belt and crankshaft sprocket. See «TIMING BELT»(ref-49061-S22953290602001011500000) under REMOVAL & INSTALLATION. Remove oil pan. See «OIL PAN»(ref-49061-S31609658272001011500000) under REMOVAL & INSTALLATION.
2. Remove thermostat housing. Remove retaining bolts, oil pump pick-up tube and "O" ring. Remove retaining bolts, oil pump and "O" ring. Remove retaining screws, pump cover and oil pump components. (Scheme 24) Drive crankshaft front seal from oil pump body (if necessary).

Scheme 24

Reassembly & Installation

1. To reassemble, coat components with engine oil. Install rotors in oil pump body. Ensure dimple on rotors face outside of oil pump body (toward cylinder block surface).
2. Install pump cover. Apply thread sealant on pump cover retaining screws, and install screws. Install plunger, plunger spring, seal and plug. Tighten oil pressure relief valve plug to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) .
3. Install crankshaft front seal (if removed) until seal surface is even with oil pump body. Coat seal lip with engine oil.
4. To install, reverse removal procedure using NEW gaskets and "O" ring. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49061-S19566747542001011500000) .