ENGINE REPAIR

Engine Assembly

REMOVAL & INSTALLATION

Except Miata

NOTE: The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recommended.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Battery cables and battery
   • Battery tray

     Fig. 1: View of typically removed external components for engine removal — front wheel drive models

   • Hood
   • Front wheels
   • Splash shield(s) from under the vehicle
4. Drain the engine and transaxle oil and the cooling system.

   Fig. 2: View of the common electrical harness plug connector points — front wheel drive models

5. Remove or disconnect the following:
   • Air cleaner assembly and resonance chamber, including the air flow meter and all of the ducting
   • Oil dipstick
6. On the Millenia with the 2.3L engine, remove the charge air cooler, front grille, upper seal board (panels that the grille mounts to) and coolant overflow tank.
7. Remove or disconnect the following:
   • Radiator hoses
   • Transmission oil cooler lines from the radiator, if equipped with automatic transaxle
   • Cooling fan and radiator switch electrical connectors
   • Radiator/cooling fan assembly
   • Throttle and speedometer cables

     Fig. 3: Typical vacuum, fuel and water hose disconnect points for engine removal — front wheel drive models

   • All vacuum hoses and wiring harnesses
   • Fuel supply and return hoses
   • Heater hoses
   • Exhaust pipe from the manifold
   • Accessory drive belt(s)
   • Power steering pump and move it aside without disconnecting the hydraulic hoses
   • Air conditioning compressor and move it aside without disconnecting the lines
   • Clutch cable and shift control rod, if equipped with manual transaxle
   • Slave cylinder from the transaxle without disconnecting the hydraulic line, if equipped with hydraulic clutch

     Fig. 4: Typically removed 4-cylinder engine under-vehicle components for engine removal — front wheel drive models

     Fig. 5: Typically removed 6-cylinder engine under-vehicle components for engine removal — front wheel drive models

   • Shift control cable, if equipped with automatic transaxle
   • Tie rod ends from the steering knuckles
   • Stabilizer bar from the lower control arms
8. Attach an engine lifting chain to the engine lifting eyes. Attach the chain to a suitable engine hoist and raise the hoist until there is tension on the chain.
9. Remove or disconnect the following:
   • Engine mount member
   • Lower ball joint from the steering knuckle
   • Bolts from the right side intermediate shaft support, if equipped
   • Intermediate shaft by prying it from the transaxle
10. Suspend the halfshafts with wire.
11. Remove or disconnect the following:
    • Dynamic damper from the right side engine mount, if equipped.
    • Engine/transaxle mount nuts/bolts and right engine (if equipped) and left transaxle mounts
12. Lift the engine/transaxle assembly from the vehicle.
13. Remove or disconnect the following:
    • Intake manifold bracket
    • Starter
    • Torque converter nuts
    • Engine-to-transaxle stiffener, if equipped
    • No. 2 engine mount
    • Throttle valve cable

      Fig. 6: Once all components and mounts are unfastened, the engine is removed with the transaxle attached — front wheel drive

    • Transaxle mounting bolts
    • Transaxle from the engine

    To install:

14. Installation is the reverse of the removal procedure. Note the following important steps.
15. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmission assembly in the vehicle.
16. Install new circlips on the inner CV-joint stub shafts, if equipped, and the intermediate shaft. Grease the shaft splines before installing the halfshaft/intermediate shaft into the transaxle.
17. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
18. Fill the engine and the transaxle with oil. Fill the cooling system.
19. Connect the negative battery cable, start the engine and check for leaks.
20. Check the ignition timing and the idle speed.
21. Check all fluid levels.

Miata

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable
   • Fresh air duct and the air cleaner/air flow meter assembly
   • Transmission
   • Accelerator cable from the throttle body
   • Undercover
4. Drain the engine oil and the cooling system.
5. Remove or disconnect the following:
   • Radiator hoses and the coolant reservoir hose
   • Cooling fan electrical connector
   • Transmission oil cooler hose, if equipped with automatic transmission
   • Radiator/cooling fan assembly
   • Accessory drive belts
   • Power steering pump and move it aside without disconnecting the hydraulic hoses
   • Air conditioner compressor and move it aside without disconnecting the refrigerant lines
6. Disconnect the following electrical connectors:
   • Steering pressure sensor electrical connector
   • Throttle position sensor electrical connector
   • Idle air control valve electrical connector
   • Heated Oxygen (HO2S) sensor electrical connector
   • Ignition coil electrical connectors
   • Crankshaft position sensor electrical connector
   • Ground electrical connectors
   • Fuel injector electrical connectors
   • Alternator electrical connectors
   • Oil pressure sensor electrical connector
   • Starter electrical connectors
7. Disconnect the following hoses:
   • Brake vacuum hose
   • Fuel hose
   • Purge control vacuum hose
   • Cruise control vacuum hose
   • Water inlet hose
   • Heater hose
   • Exhaust pipe from the exhaust manifold
8. Install suitable lifting equipment onto the engine.
9. Remove or disconnect the following:
   • Engine mount nuts
   • Engine from the vehicle

   To install:

10. Install or connect the following:
    • Engine assembly by tilting the engine downward and aligning the engine mounts with the crossmember holes. Tighten the nuts to 42–57 ft. lbs. (57–78 Nm).
    • Exhaust pipe to the manifold using a new gasket. Tighten the nuts to 34 ft. lbs. (46 Nm).
11. Connect the following hoses:
    • Brake vacuum hose
    • Fuel hose
    • Purge control vacuum hose
    • Cruise control vacuum hose
    • Water inlet hose
    • Heater hose
12. Disconnect the following electrical connectors:
    • Steering pressure sensor electrical connector
    • Throttle position sensor electrical connector
    • Idle air control valve electrical connector
    • HO2S electrical connector
    • Ignition coil electrical connectors
    • Crankshaft position sensor electrical connector
    • Ground electrical connectors
    • Fuel injector electrical connectors
    • Alternator electrical connectors
    • Oil pressure sensor electrical connector
    • Starter electrical connectors
13. Install or connect the following:
    • Air conditioner compressor and power steering pump
    • Drive belt(s)
    • Radiator and fans and all cooling system hoses
    • Accelerator cable
    • Air cleaner and air flow meter assembly
    • Transmission
    • Negative battery cable
14. Fill and bleed the cooling system.
15. Fill the engine and transmission.
16. Start the engine and check for leaks.
17. Check the ignition timing and idle speed.
18. Check all fluid levels.