Removal and installation the engine (Mazda Capella GD)

The engine and gearbox are lifted up out of the car. This job requires a lifting mechanism, but the engine can be lifted without the help of two strong people. The following description gives a brief, general explanation of engine removal. it is impossible to describe all the work for each individual model. Depending on the model, the following work is carried out:

2.1.1. Gasoline model - except DOHC engine

Figure 11 shows the removed parts regarding the numbering order. The work must be carried out using this drawing. To perform a certain task, you need to read the corresponding chapter, where it is described in detail:

• Disconnect the wire from the battery terminals and remove the battery together with the bracket, as the parts must be ready for further work.
• Unscrew the hood. Use a pencil to trace the outline of the hinge on the hood shield so that the hood will return to its original position during installation. Although it is not necessary to remove the hood, it is better if it is out of the way.
• Drain the engine oil and coolant.
• Remove the air filter. Depending on the engine version, the air filter (2) has a different design. Use a clean cloth to cover the carburetor opening to prevent foreign objects from getting inside. In a pump-carburetor engine, the intake port is not so sensitive.
• Pull the main cable (3) out of the ignition coil.
• The drive cable (4) is separated from the throttle valve.
• With the automatic system installed in the drive, separate the throttle cable (5).
• Disconnect the fuel hoses (6). Seal the free ends of the hoses with appropriate bolts to prevent fuel from leaking out. Be careful not to let any fuel leak out.
• Disconnect the upper and lower radiator hoses (7) after releasing the clamp.
• With the automatic system installed in the drive, disconnect both oil cooler hoses (8) from the water cooling.
• Disconnect the clamps from the terminals of the temperature regulator (9) in the radiator.
• Remove the radiator (10) together with the fan.
• Disconnect the engine wiring harness (11) from all terminals.
• Remove the vacuum hose (12) from the brake booster.
• Crush the three-stroke valve (13) with solenoid drive.
• Disconnect both heater hoses (15) from the front wall of the engine compartment.
• Disconnect the gearbox wiring harness (16) and move it to the side.
• Loosen the knurled nut and disconnect the tachometer coil (17).
• Disconnect the wires from the clutch cylinder head and unscrew the cylinder (18) from the gearbox.
• With the automatic system installed in the drive, disconnect the connecting cable (19).
• If there is air conditioning, after loosening the belt drive, you need to remove the drive belt together with the compressor (21) without disconnecting the hoses.
• Remove the power steering pump (22) without removing the hoses and secure it in a convenient place with a piece of wire.
• Unscrew the engine shield (23).
• Place the front of the car on jack stands and unscrew the front wheel (24).
• Separate the tie rod end (25) from the steering cam lever.
• Separate the anti-roll bar (26) from the front wheel suspension.
• Separate the wishbone at the bottom of the steering knuckle.
• To prevent damage to the drive shaft seals, they should be wrapped with a clean cloth. After this, remove both drive shafts (28) from the gearbox as described in the relevant chapter.
• With the stepped gearbox removed, unscrew the gear shift fork rod (29) and the extensions of the rod and lever system (30) from the gearbox side.
• Separate the exhaust pipe (31) from the branch pipe.
• Using a lift, raise the engine in the engine compartment. After this, unscrew the engine mount (32) from the engine and gearbox.
• Carefully lift the engine and gearbox and slowly remove it from the engine compartment. Raise the drive unit upwards. In this case, you need to make sure that connections, cables, etc. are not forgotten.

Article is based on website data [www.MazBook.ru]



If the engine freezes, you must take appropriate measures immediately. The engine is installed in reverse order, but the following points must be observed:

• Mount the engine mounts in accordance with the drawing 12 and start with the appropriate initial starting torque.

• The gear shift rod and the stabilizer of the control rod system and the gear shift mechanism control levers must be mounted in accordance with the description in the section on the gearbox.
• Lubricate the end of the drive shaft with grease, insert a new thrust ring into the groove and carefully insert the shaft into the gearbox so as not to damage the seal. After installation, grasp the disc at the end of the shaft with your hands as shown in the figure 13, and pull back and forth. This ensures that the shaft is held by the retaining ring.

• All front wheel suspension parts must be installed as described in the relevant section. Pay special attention to the fact that the end of the connecting system of the rods and the stabilizer bar arms should protrude from the top of the nut by exactly 20.1 mm, as shown in the figure 14.

• Install the clutch cylinder and bleed the air from the hydraulic system.
• Fasten the automatic transmission connecting cable according to the drawing 15. Tighten nut 1 with a force of 44-64 Nm, nut 2 with a force of 16-23 Nm.

• When installing the cooling system hoses, make sure that they do not have any cuts.
• In this case, you need to ensure that all terminals of the disconnected wiring harness are installed on the corresponding connections. Figures 16 and 17 show the methods for connecting carburetor and pump-carburetor engines. Version in the picture 16 is true for both species.

• Pour the prescribed amount of oil into the engine.
• Fill the cooling system with antifreeze from the tank.
• Turn on the engine and check for water, fuel or oil leaks.
• Set valve clearances, ignition timing, and idle speed if work has been performed that has affected these settings.

2.1.2. Gasoline model - DOHC engine

Removing and installing a DOHC engine (two overhead camshafts) is carried out in the same way as described in Chapter 2.1.1 for a conventional gasoline engine. You can use the drawing 11.

Cars with this engine are equipped with only one gearbox, and all instructions for an automatic transmission can also be used. When disconnecting individual cables, you can use the drawing 18.

2.1.3. Diesel model

Figure 19 shows the disassembled parts in the correct sequence. The work must be carried out with reference to this drawing. To complete a certain task, you need to read the corresponding chapter in which this task is described:

• Disconnect the wire connecting the battery terminal to the housing and completely remove the battery together with the bracket (1), as the parts must be prepared for the following work.
• Unscrew the hood. Use a pencil to trace the outline of the hinge on the hood shield so that the hood will return to its original position during installation. Although it is not necessary to remove the hood. it would be better if it doesn't interfere.
• Drain the engine oil and coolant.
• Remove the accelerator drive cable (2).
• Remove the air filter.
• Disconnect the wiring harness from the radiator (4).
• Remove the radiator together with the fan.
• Disconnect the vacuum hose from the brake booster (servo brake).
• Disconnect the fuel hoses (9). Plug the free ends of the hoses to prevent fuel from leaking out.
• Remove the drive belt cover (10).
• Remove the power steering pump (11) without disconnecting the hoses and secure it with a piece of wire from the engine compartment side.
• Remove the engine mount (12).
• Unscrew the hydraulic system in the place shown in the figure 20. and disconnect the clutch cylinder (13).

• Loosen the knurled nut and disconnect the tachometer spiral (14).
• Disconnect the gearbox wiring harness (15).
• If there is air conditioning, after loosening the belt drive, you need to remove the drive belt and compressor together with the compensator (16) without disconnecting the hoses. Secure the compressor in a convenient place with wire.
• Disconnect the engine wiring harness.
• Disconnect the heater hose (18) and remove.
• Place the front of the car on jack stands and unscrew the front wheels.
• Unscrew the engine casing shield (20).
• Disconnect the tie rod end (21) from the steering knuckle lever.
• Disconnect the stabilizer bar (22) from the front wheel suspension.
• Disconnect the transverse suspension arm (23) at the bottom of the steering knuckle.
• To prevent damage to the drive shaft seals, they should be wrapped in a clean cloth. After this, remove both drive shafts (24) from the gearbox as described in the relevant chapter.
• Unscrew the gear shift fork rod (25) and the extension system of rods and levers (26) from the gearbox side.
• Separate the exhaust pipe (27) from the branch pipe.
• Using a skidding loop, hang the engine on the lift and lift the drive unit. After this, unscrew the engine mount (28) from the engine and gearbox
• Carefully lift the engine and gearbox and slowly remove it from the engine compartment. Raise the drive unit upward. At the same time, make sure that the connections are not forgotten. cables, etc.
• If the engine is stuck, you must take appropriate measures immediately.

The engine is installed in reverse order, but the following points must be observed:

• Mount the engine mount in the same way as shown in the figure 12. Maintain the same tightening torques.
• Mount the gear shift rod and the stabilizer of the control rod system and the gear shift mechanism control levers in accordance with the description in the section on the gearbox
• Lubricate the end of the drive shaft with grease, insert a new thrust ring into the groove and carefully insert the shaft into the gearbox so as not to damage the seal. After installation, grasp the disc at the end of the shaft with your hands as shown in the figure 13. and pull forward and backward. This ensures that the shaft is held by the snap ring.
• All front wheel suspension parts must be installed as described in the relevant section. Pay special attention to that. that the end of the connecting system of the rods and the arms of the anti-roll bar should protrude from the upper nut by exactly 20.1 mm, as shown in the figure 14.
• Install the clutch cylinder and screw on the hydraulic system (figure 20)

2.1.4. Separating the gearbox from the engine

For all types of engines, work is carried out in a similar manner. Unscrew the starter and remove it. On standard and diesel engines, under the clutch cylinder and reinforcing clamps on the left and right, unscrew the housing shield. In addition, the diesel engine has a hose screwed onto the clamp on one side. Remove the connecting bolts between the engine and gearbox and pull the gearbox forward away from the engine. so as not to load the shaft.

For a DOHC engine, you only need to remove the starter, loosen the bolts and pull out the gearbox.

When connecting the gearbox to the flanges, observe the following tightening torques:

• Standard engine: Reinforcement clamp on engine 37-52 Nm. Gearbox on engine 90-120 Nm, shield of the housing for the clutch housing 8-11 Nm.
• DOHC engine: gearbox on the engine below 37-52 Nm. gearbox on the engine above 90-120 Nm.
• Diesel engine: reinforcing clamp on the engine 37-52 Nm. Gearbox on the engine at the top 90-120 Nm. Gearbox on the engine at the bottom 37-52 Nm. Bolts with the body 55-80 Nm, clamp on the bracket 8-11 Nm.