2.0L 4-CYL: Removal & Installation Mazda MX-6 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 residual pressure from fuel system. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain cooling system and transaxle. Remove hood and front wheels. 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. Leaving hoses attached, remove power steering pump and A/C compressor. Tie components out of way with wire.
3. Disconnect necessary electrical connectors, hoses and cables. On A/T, disconnect shift cable from transaxle. On M/T, remove clutch release cylinder with hose attached and tie out of way with wire. On all vehicles, remove transverse member (crossmember) from below engine.
4. Remove nuts securing engine mounts to engine mount member (large support piece that runs from front to rear under flywheel 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 vehicles, disconnect stabilizer bar and tie rod ends. Separate ball joints from steering knuckles. Remove drive shafts. See «AXLE SHAFT - FRONT»(ref-43497) article in DRIVE AXLES section. Remove engine compartment fuse/relay block.
6. Remove engine mount No. 1 stay bracket. (Scheme 38) Remove engine mount No. 3 rubber. Remove engine mount No. 1 bolts. Remove engine mount No. 4 rubber 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. Prime fuel system before attempting to start engine. See FUEL PRESSURE RELEASE. Bleed cooling system. See COOLING SYSTEM BLEEDING.

Scheme 38

Release residual pressure from fuel system. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Drain cooling system. Remove air intake duct. Disconnect necessary electrical connectors, hoses and cables. Remove intake manifold 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. 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. Disconnect negative battery cable. Drain cooling system. Remove hood and engine undercover. Remove air intake hose and air cleaner assembly. Disconnect necessary electrical connectors, hoses and control cables. CAUTION: To prevent cylinder head warpage or cracking, loosen cylinder head bolts in proper sequence. (Scheme 39)
2. Remove timing belt. See TIMING BELT. Remove distributor. Remove camshafts. See CAMSHAFTS. Remove intake manifold bracket. Loosen cylinder head bolts in proper sequence, in 2-3 steps. (Scheme 39) 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 40) See TORQUE SPECIFICATIONS.
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. Prime fuel system before attempting to start engine. See FUEL PRESSURE RELEASE. Bleed cooling system. See COOLING SYSTEM BLEEDING. Set ignition timing.

Scheme 39

Scheme 40

Remove timing belt. See TIMING BELT. Remove crankshaft sprocket. Cut oil seal with razor 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 front cover. To install remaining components, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.

1. Disconnect negative battery cable. Remove right front wheel and engine undercover. Leaving hoses attached, remove power steering pump and tie it out of way with wire. Remove water pump pulley. Remove crankshaft pulley and guide plate (large washer).
2. Remove spark plug wires and spark plugs. Loosen valve cover bolts in proper sequence, in 2-3 steps. (Scheme 41) Remove valve cover and gasket. Remove dipstick tube. Remove upper and lower timing belt covers. Support engine from above. Remove engine mount at timing belt end of engine.
3. If reusing timing belt, mark arrow on belt to indicate direction of rotation. Install crankshaft pulley bolt finger-tight to retain crankshaft sprocket. Rotate crankshaft clockwise (as viewed from timing belt end of engine) until cylinder No. 1 piston is at TDC of compression stroke and timing marks are aligned. (Scheme 43)
4. Turn tensioner clockwise with an Allen wrench to relieve spring tension, and then disconnect spring. Remove timing belt. Remove crankshaft sprocket, tensioner and idler pulley (if necessary).

1. Install crankshaft sprocket, tensioner, water pump pulley and idler pulley (if removed). Temporarily tighten tensioner with spring fully retracted. Ensure timing marks are aligned. (Scheme 43) Install timing belt around crankshaft sprocket, water pump sprocket, idler pulley and camshaft sprockets. Ensure slack does not exist on idler side (tension side) of timing belt.
2. Complete timing belt installation on slack side. Loosen tensioner bolt and allow tensioner to ride against timing belt. Tighten tensioner bolt to specification. See TORQUE SPECIFICATIONS. Rotate crankshaft clockwise 2 turns. To install remaining components, reverse removal procedure.

Scheme 41

Scheme 42

Scheme 43

Disconnect negative battery cable. Remove timing belt. See TIMING BELT . Remove camshafts. See CAMSHAFTS. Mark Hydraulic Lash Adjusters (HLA) for installation to original location. Remove HLA. Store HLA in normal upright position, submerged in clean engine oil.

Apply oil to friction surfaces. Install HLA in original locations. Ensure each HLA slides freely in bore. To complete installation, 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 44) Loosen camshaft bearing cap bolts 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 (exhaust camshaft has distributor drive gear on it). 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 2-3 steps, starting at center and working outward. See TORQUE SPECIFICATIONS.
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 43)

Scheme 44

Drain engine oil. Remove transmission and flexplate/flywheel. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in the TRANSMISSION/TRANSAXLE section.

TRANSMISSION REMOVAL & INSTALLATION - A/T

TRANSMISSION REMOVAL & INSTALLATION - M/T

Cut oil seal with razor 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.
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.

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

For removal and installation procedures (Scheme 45)

Scheme 45

For removal and installation procedures (Scheme 46)and (Scheme 47).

Scheme 46

Scheme 47

1. Disconnect negative battery cable. Remove engine splash shield. 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 an oil pan bolt into this weld nut to create a small gap between oil pan and cylinder block. Separate oil pan from oil pan upper block with a screwdriver, being careful not to damage sealing surfaces. Remove oil pan. (Scheme 48) Remove oil strainer (if necessary).

1. Install oil strainer and NEW gasket (if removed). Tighten oil strainer bolts to specification. See TORQUE SPECIFICATIONS. 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.

Remove oil pan. See OIL PAN. Remove 2 nuts from rear end of cylinder block. Loosen oil pan upper block bolts in proper sequence, in 2-3 steps. (Scheme 49) Separate oil pan upper block from cylinder block using screwdriver, 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. See TORQUE SPECIFICATIONS. Tighten oil pan upper block bolts to specification in sequence, in 2-3 steps. (Scheme 50) To install remaining components, reverse removal procedure.

Scheme 48

Scheme 49

Scheme 50

Removal & Disassembly

1. Remove timing belt and crankshaft sprocket. See TIMING BELT 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 51) 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 52) 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.
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. To complete installation, reverse removal procedure.

OIL PUMP SPECIFICATIONS

Scheme 51

Scheme 52