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Home >> Mazda Truck >> 2009 >> B4000 V6-4.0L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement

Removal and Replacement



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ENGINE REMOVAL / INSTALLATION - 4.0L

Removal

All vehicles

1. Disconnect the battery. See Procedures.

2. Remove the intake manifold. See - Service and Repair.

3.

CAUTION:If used as a leverage device, the fuel rail can be damages. Care must be taken when working around the fuel rail.Disconnect the spring lock couplings. See Spring Lock Couplings.

- Detach the fuel tube from the bracket.

4. Using the spark plug wire remover SST, disconnect the spark plug wires from the spark plugs.






5. Detach the spark plug wire retainer from the LH valve cover stud and remove the ignition coil, bracket and LH spark plug wires as an assembly.






6. Detach the spark plug wire retainer from the RH valve cover stud and remove the RH spark plug wires.






7.
NOTE:Mark the hinge locations for installation reference.Remove the hood.

8. If the vehicle is equipped with A/C, discharge and recover the A/C system. See A/C Refrigerant System Tests.

9. Disconnect the mass air flow (MAF) sensor electrical connector.






10. Remove the fan blade. See - Service and Repair.

11. Remove the air cleaner housing cover.






12. Remove the radiator. See - Service and Repair.

13. If the vehicle is equipped with A/C, disconnect the A/C field coil electrical connector.

14. If the vehicle is equipped with A/C, disconnect the A/C high pressure switch electrical connector.






15. If the vehicle is equipped with A/C, remove the bolt and position the A/C hoses aside.






16. Remove the accessory drive belt. See - Service and Repair.

17. Disconnect the high pressure hose from the lower power steering pump fitting.






18.
NOTE:The battery is removed for clarity.Disconnect the power steering return hose from the power steering fluid reservoir.






19. Remove the accessory bracket bolts and the bracket, the A/C compressor, if equipped, the power steering pump and the power steering reservoir as an assembly.






20. Disconnect the generator electrical connections.






21. Disconnect the wiring harness retainer and position generator wiring away from the engine.

22. Remove the bolt and disconnect the engine wiring harness electrical connector.






23. Disconnect the 2 engine wiring harness electrical connectors






24. Remove the engine ground wire nut.






25. Disconnect the vapor hose from the purge valve and remove the hose.






26. Remove the crankcase breather hose and disconnect the two vacuum hoses (one shown) and remove the vacuum hose harness.






27.
NOTE:Heater hose will be removed with engine.Disconnect the heater hose.






28. Disconnect the heater hose.






Vehicles equipped with an automatic transmission

1. Remove the transmission level indicator tube nut.






All vehicles

1. Remove the starter motor. See - Service and Repair.

2.
NOTE:2WD shown, 4WD similar.Remove the bolt and detach the wiring harness bracket. Disconnect the oil pressure sensor electrical connector.






Vehicles equipped with an automatic transmission

1. Disconnect the RH catalyst monitor sensor electrical connector, remove the nut and route the bracket and wiring harness over the transmission.






2. Disconnect the LH catalyst monitor sensor and the transmission electrical connectors. Detach the wiring harness retainers.






3. Remove the bolt and position the transmission cooling tube bracket aside.






4. Remove the four torque converter nuts.






Vehicles equipped with a manual transmission

1. Disconnect the RH catalyst monitor sensor electrical connector, remove the nut and route the bracket and wiring harness over the transmission.






2. Disconnect the LH catalyst monitor sensor and the transmission electrical connectors. Detach the wiring harness retainers.






All vehicles

1. Disconnect the electrical connector and detach the wiring harness retainer from the crossmember. Make sure all the electrical connectors and wiring harness retainers are disconnected and route the transmission wiring to the top of the engine.






2. Drain the engine oil.

3. Install the oil drain plug.






4. Remove the oil filter.

5. Disconnect the LH HO2S electrical connector.






6. Disconnect the RH HO2S electrical connector.






7.
NOTE:LH shown, RH similar.Remove the 4 exhaust manifold-to-dual converter Y-pipe nuts.






8. If equipped with A/C, remove the A/C tube bracket nut and position it aside.






9.
NOTE:Automatic transmission shown, manual transmission similar.Remove the eight bolts.






10. Remove the RH engine insulator nuts.






11. Remove the LH engine insulator nuts.






12. Install the left side lifting eye SST.






13. Install the right side lifting eyeSST.






14. Install the spreader bar to the lifting eyes.

15. Position a floor jack under the bell housing of the transmission.

16. Attach a floor crane to the spreader bar and remove the engine.

Installation

All vehicles

CAUTION:If used as a leverage device, the fuel rail can be damaged. Care must be taken when working around the fuel rail.
1. Install the engine, remove the floor crane and the spreader bar.

2. Remove the engine lifting brackets.

3. Install the LH engine insulator nuts.






4. Install the RH engine insulator nuts.






5.
NOTE:Automatic transmission shown, manual transmission similar.Install the eight transmission-to-engine bolts.






6. If equipped with A/C, position the A/C tube bracket and install the nut.






7.
NOTE:LH shown, RH similar.Install the 4 exhaust manifold-to-dual converter Y-pipe nuts.




Tightening torque:40 Nm {4.1 kgf-m, 30 ft-lbf}

8. Connect the RH heated oxygen sensor (HO2S) electrical connector.






9. Connect the LH HO2S electrical connector.






10. Install a new engine oil filter.

11. Route the transmission wiring harness from the top of the engine to the transmission.

12. Attach the wiring harness to the crossmember and connect the electrical connector.






Vehicles equipped with a manual transmission

1. Connect the LH catalyst monitor sensor electrical connector and attach the wiring harness retainers.






2. Route the wiring harness over the transmission and position the bracket on the stud. Install the nut and connect the RH catalyst monitor sensor electrical connector.




Tightening torque:10 Nm {1.0 kgf-m, 89 in-lbf}

Vehicles equipped with an automatic transmission

1. Install the four torque converter nuts.






2. Position the transmission cooling tube bracket and install the bolt.






3. Connect the transmission and LH catalyst monitor sensor electrical connectors. Attach the wiring harness retainers.






4. Route the wiring harness over the transmission and position the bracket on the stud. Install the nut and connect the RH catalyst monitor sensor electrical connector.




Tightening torque:10 Nm {1.0 kgf-m, 89 in-lbf}

5. Position the transmission level indicator tube and install the nut.






All vehicles

1.
NOTE:2WD shown, 4WD similar.Install the engine wiring harness bracket and bolt and connect the oil pressure sensor electrical connector.




Tightening torque:10 Nm {1.0 kgf-m, 89 in-lbf}

2. Install the starter. See - Service and Repair.

3. Connect the heater hose.






4. Connect the heater hose.






5. Position the vacuum hose harness and connect the 2 vacuum hoses (1 shown). Install the crankcase breather hose.






6. Connect the vapor hose to the purge valve.






7. Position the engine ground wire and install the nut.




Tightening torque:10 Nm {1.0 kgf-m, 89 in-lbf}

8. Connect the 2 engine wiring harness electrical connectors.






All vehicles

1. Position the wiring harness and install the bolt.






2. Connect the generator wiring.






3. Position the accessory bracket, the A/C compressor if equipped, and the power steering pump and power steering fluid reservoir as an assembly and install the accessory bracket bolts.






4.
NOTE:The battery is removed for clarity.Connect the power steering return hose to the power steering fluid reservoir.






5. Connect the power steering high pressure hose to the lower power steering pump fitting.






6. If equipped with A/C, position the A/C compressor manifold tube and install the bolt.






7. If equipped with A/C connect the A/C high pressure switch electrical connector.






8. If equipped with A/C, connect the A/C field coil electrical connector.

9. Install the accessory drive belt. See - Service and Repair.

10.
NOTE:Do not fill the cooling system at this time.Install the radiator. See - Service and Repair.

11. Install the air cleaner housing cover.






12. Connect the mass air flow (MAF) sensor.






13. Install the fan blade. See - Service and Repair.

14. Install the hood.

15. Position the RH spark plug wires and attach the retainer to the RH valve cover stud. Coat the inside of the spark plug boots with Silicone Brake Caliper Grease and Dielectric Compound and connect the spark plug wires to the correct spark plugs.

16. Position the ignition coil, the bracket and he LH spark plug wires and attach the spark plug wire retainer to the LH valve cover stud. Coat the inside of the spark plug boots with Silicone Brake Caliper Grease and Dielectric Compound and connect the spark plug wires to the correct spark plugs.

17. Connect the spring lock couplings. See Spring Lock Couplings.

18. Install the intake manifold. See - Service and Repair.

19. Connect the battery. See Procedures.

20. Fill the engine to the correct oil level with clean engine oil.

21. Fill the engine cooling system. See - Removal and Replacement.

22. Fill the power steering system. See Power Steering System Filling.

23. If equipped with A/C, recharge the A/C system. See A/C Refrigerant System Tests.

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