Mazdamanuals.com

ENGINE REMOVAL/INSTALLATION [SKYACTIV-D 1.8]

Home  id0110t1800400

Replacement Part

Warning

•  A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.

―  Fuel may cause irritation if it comes in contact with skin and eyes.

―  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

Caution

•  If the intake-air system, exhaust system, or the engine is damaged, fragments of the damaged part may be remaining in the intake-air system or exhaust system. If the engine is replaced without removing fragments of the damaged part, it could cause engine damage or malfunction. Before replacing the engine, verify that no fragments remain in the parts to be reused.

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

Note

•  Perform the engine and transaxle component removal/installation from the lower side of the vehicle after removing the front crossmember component.

Operation After Replacing Engine

1.  After replacing the engine, perform the following procedure.

STEP	ACTION	PAGE/CONDITION
1	Perform KOEO self-test procedure.	(See DTC INSPECTION.)
2	Start the engine.	—
3	Verify that the check engine light does not illuminate.	—
4	Perform KOER self-test procedure.	(See DTC INSPECTION.)
5	Perform fuel injector injection amount correction.	(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 1.8].)
6	Perform timing chain learning procedure.	(See TIMING CHAIN LEARNING [SKYACTIV-D 1.8].)
7	Clear the DTCs.	(See BASIC KNOWLEDGE.)
8	Switch the ignition off.	—

Removal/Installation

Caution

•  Do not apply oil (such as engine oil, ATF) to the O-ring. Otherwise, the O-ring could swell causing a seal malfunction.

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

3.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

•  Air hose

•  Air cleaner cover

•  Air cleaner element

•  Air cleaner case

•  Fresh-air duct

4.  Remove the bolts, nut and connector shown in the figure, and set the wiring harness aside.

ac3wzw00001742

5.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

6.  Disconnect the ground cable shown in the figure.

RH

am3zzw00034385

LH

am3zzw00030383

7.  Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

8.  Drain the engine coolant and the coolant in the water-cooled charge air cooler. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 1.8].) (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [SKYACTIV-D 1.8].)

9.  Drain the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].(MTX)) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [ET6A-EL, ET6AX-EL (E)].(ATX))

10.  Drain the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [C66MX-R].)

11.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

12.  Remove the cooling fan component. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

13.  Disconnect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION [(E)].)

14.  Disconnect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

15.  Remove the clutch release cylinder with the pipe still connected. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

16.  Disconnect the vacuum hose on the engine side. (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

17.  Disconnect the fuel main hose and fuel return hose No.1 from lower case. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

18.  Disconnect the water-cooled charge air cooler water hose from radiator. (upper, lower) (See WATER-COOLED CHARGE AIR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

19.  Disconnect the heater hose from body side. (See A/C UNIT REMOVAL/INSTALLATION [(E)].)

20.  Remove the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

21.  Remove the front under cover No.1 and No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

22.  Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

23.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

24.  Remove the bolt of the lower radiator hose component.

ac3wzw00001745

25.  Remove the lower radiator hose component.

am2zzw00010099

26.  Set the cooler hose (LO) aside. (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

27.  Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

28.  Remove the middle pipe/Ammonia slip catalyst installation nut (catalytic converter side) and secure the middle pipe/Ammonia slip catalyst using wire or rope so that it is out of the way. (2WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

29.   Remove the middle pipe. (AWD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

30.  Remove the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION [(E)].)

31.  Disconnect the front drive shaft (LH) from the transaxle side and set the drive shaft (LH) out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(E)].)

32.  Disconnect the front drive shaft (RH) from the transaxle side and set the drive shaft (RH) out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(E)].) (2WD)

33.   Remove the front drive shaft (RH). (AWD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(E)].)

34.  Remove in the order indicated in the table.

35.  Install in the reverse order of removal.

36.  Refill the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [C66MX-R].)

37.  Refill the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].(MTX)) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [ET6A-EL, ET6AX-EL (E)].(ATX))

38.  Refill with engine coolant and water-cooled charge air cooler coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 1.8].) (See WATER-COOLED CHARGE AIR COOLER COOLANT REPLACEMENT [SKYACTIV-D 1.8].)

39.  If the engine is replaced, perform “Operation After Replacing Engine”. (See Operation After Replacing Engine.)

40.  Start the engine, and inspect and adjust the following:

•  Front wheel alignment (See FRONT WHEEL ALIGNMENT [(E)].)

•  Leakage of engine oil, engine coolant, water-cooled charge air cooler coolant, transaxle oil (MTX), ATF (ATX), and fuel

•  Runout and contact of pulley and belt

•  Idle speed (See ENGINE TUNE-UP [SKYACTIV-D 1.8].)

•  Engine-driven accessories operation

Note

•  If the engine is overhauled and assembled to the vehicle, perform a road test to verify that there is no abnormal vibration and noise.

am3zzw00034386

1	No.4 engine mount component (See No.3 engine mount, No.4 engine mount component removal note.) (See Engine mount installation note.)
2	No.3 engine mount (See No.3 engine mount, No.4 engine mount component removal note.) (See Engine mount installation note.)
3	Engine, transaxle

No.3 engine mount, No.4 engine mount component removal note

1.  Remove the insulator. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

2.  Remove the PCM and PCM bracket. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

3.  Remove the bolts shown in the figure and remove the PCM bracket.

am3zzw00030397

4.  Remove the seal plate installed to the underside of the oil pan. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

Caution

•  When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent deformation of the oil pan and damage of the transaxle.

5.  Secure the engine and transaxle using a commercially available engine lifter.

am2zzw00010107

6.  Remove the No.4 engine mount bracket.

7.  Remove the No.3 engine mount.

Engine mount installation note

Caution

•  Slots have been adopted for the No.3 engine mount and No.4 engine mount bracket installation holes. Tighten the installation bolts and nuts so that they are centered on the slots. Otherwise, engine noise or vibration could increase.

Note

•  When loosening the nuts of the No.3 engine mount and the No.4 engine mount bracket, the engine front cover and the transaxle stud bolt may loosen.

1.  Tighten the engine front cover stud bolts.

am3zzw00030388

2.  Measure the projection of the transaxle stud bolts. (MTX)

•  If the projection amount is not within the range, adjust the projection amount of the stud bolt.

am3zzw00030389

3.  Tighten the transaxle stud bolts. (ATX)

am3zzw00030390

Caution

•  When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent deformation of the oil pan and damage of the transaxle.

4.  Secure the engine and transaxle using a commercially available engine lifter.

am2zzw00010107

5.  Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:

(1)  Temporarily tighten the bolts shown in the figure so that they are centered on the No.3 engine mount slots.

am3zzw00030391

6.  Temporarily tighten the No.4 engine mount rubber installation bolts and nuts using the following procedure:

(1)  Temporarily tighten the bolts and nuts shown in the figure so that they are centered on the No.4 engine mount rubber slots.

•  If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the transaxle, and temporarily tighten the installation nuts.

MTX

am3zzw00030392

ATX

am3zzw00030393

7.  Temporarily tighten the No.4 engine mount bracket installation bolts.

8.  Install the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)

Note

•  At this stage, only temporarily tighten the No.1 engine mount rubber, do not tighten it completely.

9.  Tighten the No.3 engine mount installation bolts and nuts shown in the figure.

am3zzw00030394

10.  Tighten the No.4 engine mount bracket and rubber installation bolts and nuts in the order shown in the figure.

ac30zw00004857

11.  Tighten the No.1 engine mount rubber installation bolts.

ac30zw00005295

12.  Install the seal plate. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)

13.  Install the PCM bracket using the following procedure:

am3zzw00030397

(1)  Temporarily tighten the bolt A.

(2)  Tighten the bolts in the order of B and A.

14.  Install the PCM and PCM bracket. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 1.8].)