Complete engine teardown to bare shortblock how-to with pictures
 

Here is a writeup to go with my engine removal how-to elsewhere. After the engine is pulled out of the car in it's complete form, you'll usually be either rebuilding the existing engine block, or using another engine block that is either used or rebuilt. So you need to get all your accessories off your block. There are many ways of doing this, but this method is the most efficient and probably the fastest. Knowing exactly in what order to do things and where each bolt and plug is helps a lot.

This also assists customers of mine who wish to send in their engine block for rebuild. Although I do offer a "longblock" service whereby customers can send their complete engine (as shown below), the general industry standard for non-mazda rebuild shops is for the customer to supply or exchange a bare shortblock, which is what you will end up with at the end of this writeup.

When it is engine rebuild time for you guys, remember which builder took time to photo document, transcribe, and post this procedure for free on your forum for your assistance. :)

First we have the engine hanging here on the hoist exactly as I pull it out of the car.

http://www.rotaryresurrection.com/kl...l/DSCF4680.JPG

Now, I will obviously be using an engine stand, although it is NOT a requirement...it just makes things easier and less messy. A few things have to be removed before the engine stand head can be mounted.

Remove the front oil cooler line.

Remove the 12mm bolt holding the engine ground bracket to the bottom of the intermediate iron on the driver side.

Remove the retaining clip and unplug the oil level sensor in the drivers side of the oilpan. This wire is clipped onto the aforementioned bracket, so separate this clip from the bracket.

Remove the 3 10mm bolts holding down the coil brackets to the front cover. UNplug the 4 coils and the plug wires. Remove the 12mm bolt holding the alternator wire on to the alternator, remove the clip holding that wire to the front cover, and remove the whole harness with coils etc.

http://www.rotaryresurrection.com/kl...n/DSCF4683.JPG

At this point the engine can be mounted on the engine stand.

http://www.rotaryresurrection.com/kl...n/DSCF4684.JPG

Unbolt knock sensor from rear rotor housing. Remove spark plugs. Use a 24mm socket to remove the oil pressure sending unit.

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Remove rear heater core hose from pipe on rear iron.

http://www.rotaryresurrection.com/kl...n/DSCF4686.JPG

Remove air control valve...disconnect vacuum hose, remove bolt on top bracket, and 2 nuts/studs on exhaust manifold. Disconnect wiring harness clip. On some cars the two nuts/studs on the exhaust manifold will be rusty, or you may round off the nuts...in this case it is fine to leave the ACV bolted onto the manifold and remove them as a pair.

http://www.rotaryresurrection.com/kl...n/DSCF4687.JPG

Remove exhaust manifold and gasket. DO not worry if the studs come out with the nuts, this is common and you can reinstall them together too.

http://www.rotaryresurrection.com/kl...n/DSCF4688.JPG

Remove both fuel lines from the retaining clips under the intake manifold on the drivers side. Simply pry the clips apart with a small screwdriver.

http://www.rotaryresurrection.com/kl...n/DSCF4689.JPG

Use a long extension and socket to remove the 2) 10mm bolts facing down from the retaining clip under the intake manifold.

http://www.rotaryresurrection.com/kl...n/DSCF4690.JPG

Remove upper intake manifold. Disconnect vacuum hose from the rear drivers side, 5 bolts on passenger side top, plug to vacuum solenoid on top front behind the oil filler neck, 1 coolant hose on top of the throttlebody and 1 coolant hose on the bottom of the throttlebody. Unplug the electrical connector to the throttlebody. Lift upper intake/throttlebody combo off carefully.

http://www.rotaryresurrection.com/kl...n/DSCF4691.JPG

remove oil filler neck. Remove 3 solenoid plugs from the back, 2 vacuum solenoids from port actuators, harness clip, and 2 nuts at base of the neck.

http://www.rotaryresurrection.com/kl...n/DSCF4692.JPG

Remove extension manifold...

http://www.rotaryresurrection.com/kl...n/DSCF4693.JPG

Remove a/c belt tensioner from front cover. Unbolt crank angle sensor and remove clips holding harness to front cover. Lay aside on top of the engine harness.

http://www.rotaryresurrection.com/kl...n/DSCF4694.JPG

Unplug alternator plug.

http://www.rotaryresurrection.com/kl...n/DSCF4695.JPG

Remove air hose to vacuum splitter at the base of the primary fuel injector rail. BE CAREFUL with the black plastic vacuum splitter...it is going to be brittle and easily broken.

http://www.rotaryresurrection.com/kl...n/DSCF4696.JPG

Unplug all 6 fuel injectors (4 for automatic 4port models)...LABEL EACH INJECTOR AND PLUG (or draw yourself a chart etc.) for clarification later as they can be easy to mix up. The connectors are pretty hard to work with and release, and sometimes you will break the release tab. I find that a long pair of needle nose pliers is helpful here. The other approach is to simply leave the harness plugged into all the injectors (so you do not risk damage to the plugs or mixing them up) and pull the lower intake manifold, wiring harness, and both fuel rails/injectors all off as a set. IT is more difficult to work with this way, but it could save you some headache down the road.

http://www.rotaryresurrection.com/kl...n/DSCF4697.JPG

Unplug and remove from bracket, the plug for the microswitch on the port actuator. Unplug coolant temp sensor. Unplug aux port actuator solenoid.

Remove water pump pulley.

http://www.rotaryresurrection.com/kl...n/DSCF4698.JPG

Remove alternator bracket and alternator.

http://www.rotaryresurrection.com/kl...n/DSCF4699.JPG

BE CAREFUL OF THE OMP (OIL METERING PUMP) AND THE BLACK PLASTIC POSITION SENSOR ON THE SIDE OF IT. Shops and DIY'ers are somehow breaking this position sensor during r/r of the engine. I am not sure how, since it does not really come close to anything on the way in or out. Regardless, if you damage the position sensor it cannot be purchased separately to my knowledge, so then you must buy a whole OMP. Mazda retails that part for over $1000 new, and used ones go for $200-300 or more so this is a mistake you want to avoid. Unplug OMP connectors, unclip harness from front cover, lift and lay aside with rest of engine wiring harness.

http://www.rotaryresurrection.com/kl...n/DSCF4700.JPG

Unbolt harness retaining bracket from top of block (4 bolts total) and remove bracket/harness as a unit (if you unplugged your injectors).

http://www.rotaryresurrection.com/kl...n/DSCF4701.JPG

Remove fuel line between primary and secondary fuel rail, at secondary fuel rail blue clip.

http://www.rotaryresurrection.com/kl...n/DSCF4702.JPG

Unbolt and remove lower intake manifold, being careful of auxiliary port sleeves that come out of the block with the manifold. Sometimes it takes several tugs and pushes to get these out of the block when they are stuck due to carbon. On rare occasion I find a stuck sleeve that will not come out of the block, and in this case generous amounts of penetrating oil (wd40 etc.) sprayed down the appropriate intake runner and between the block and gasket/manifold, as well as gentle prying and rocking of the manifold will eventually help get it out.

IF you are leaving the wiring connected to all the injectors, then pull the manifold halfway out of the block to give yourself enough access to unbolt the primary fuel injector rail then pull it off with the rest of the wiring/manifold.

http://www.rotaryresurrection.com/kl...n/DSCF4703.JPG

http://www.rotaryresurrection.com/kl...n/DSCF4704.JPG

Remove primary fuel rail/injectors. Note that there are two black rubber grommets/seals that go on the bottom of the primary injectors. These often stick in the holes in the engine block/intermediate iron. Use a small screwdriver or pick to gently fish them out of the block, they are reusable and you need to be sure they are properly seated on the injectors during re-install.

BE CAREFUL OF THE BLACK PLASTIC VACUUM SPLITTER mounted under the primary fuel rail. There are 4 vacuum hoses that go to each oil injector/nozzle. DO NOT try to remove these vacuum hoses from the plastic splitter, or you will likely break one. Instead, remove the vacuum hoses from the injectors themselves, and do it gently. I use needle nose pliers to grip the base of the hose firmly and twist, then gently pull upward while twisting. IF you feel you must remove the vacuum hoses from the plastic splitter, use a razor blade to cut into the hose and then peel it off of the plastic nipple.

http://www.rotaryresurrection.com/kl...n/DSCF4705.JPG

Remove rear oil cooler line and oil filter pedestal as a unit.

http://www.rotaryresurrection.com/kl...n/DSCF4706.JPG

Remove small rear coolant line from passenger side of rear iron.

http://www.rotaryresurrection.com/kl...n/DSCF4707.JPG

Remove clutch and flywheel. If you are sending an engine to me (or most other engine builders) you can leave the flywheel in place for me to remove for you, as it requires a special socket to remove, so it is understandable if individuals cannot remove it themselves.

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Remove the oil injector nozzles with a 19mm wrench. BE CAREFUL when loosening them. IF you hit them hard/fast you will likely snap one or more of the plastic oil lines. GENTLY bump your wrench to crack the nozzles only slightly loose, and continue until you are sure you won't break a line. You can use a finger placed against the metal end of the oil line to brace it and keep it from flexing too much during this step. These lines retail for $55 each from mazda if you do break them.

http://www.rotaryresurrection.com/kl...n/DSCF4710.JPG

Remove OMP lines and OMP as a unit. BE CAREFUL OF THE OMP (OIL METERING PUMP) AND THE BLACK PLASTIC POSITION SENSOR ON THE SIDE OF IT. Shops and DIY'ers are somehow breaking this position sensor during r/r of the engine. I am not sure how, since it does not really come close to anything on the way in or out. Regardless, if you damage the position sensor it cannot be purchased separately to my knowledge, so then you must buy a whole OMP. Mazda retails that part for over $1000 new, and used ones go for $200-300 or more so this is a mistake you want to avoid.

http://www.rotaryresurrection.com/kl...n/DSCF4711.JPG

remove thermostat housing and lines as a unit.

http://www.rotaryresurrection.com/kl...n/DSCF4712.JPG

Top end is now stripped.

http://www.rotaryresurrection.com/kl...n/DSCF4713.JPG

http://www.rotaryresurrection.com/kl...n/DSCF4714.JPG

Flip the engine over, remove the oil pan and pickup tube. Use a stiff putty knife and hammer it between the engine and oil pan in one corner. Then hammer the putty knife from the side, all around the oilpan perimeter, to break the bond without having to pull and pry on the pan and warp the flange.

http://www.rotaryresurrection.com/kl...n/DSCF4715.JPG

Engine is now stripped and ready to be disassembled or returned as a core.

Good work . Will keep this handy for next time i take the engine out

BTW that engine looks to have some serious oil control issues !!!

Oil o-ring failure on the rear rotor?

More epicness...

excellent DIY RR.
I'm hoping I never need this info but if I do....


Thanks.

oil starvation to rear rotor and rear main...destroyed both adjacent irons, rotor, shaft, all bearings, rear rotor oil control rings, cutoff rings, and side seals.

Here is the teardown if you're interested in looking, but I warn you, it's ugly...

http://www.rotaryresurrection.com/builds.php/campos

Wow good read. Thanks for posting this.

wow ... just finished looking at those pics. 1/2 of them are trash :(

Excellent thread....

i can't wait to get my hands on one of these things!

i hate because i have no skills near this..

hmmm.....

I'm gonna need this detailed DIY. I just got my work messed up following just indtructions without any illustrations.
_______________________________________________
Hit the Road with SEMO

Wat?

Now thats a real do it your selfer :rofl:

Wat?

How many miles where on the engine when you started taking it apart?

I would so purchase a bolt kit for all the bolts used in this tear-down, if it was available. It would be awesome to have a set in a bag labeled for what they are.

I have a project I could use them on. ;)

the parts PDFs which will show what and where

Now you're getting crazy :) You going to ceramic coat the bolt heads? :lol:

I was thinking something along those lines... :rolleyes:

Best advice if you are on a budget low miles van at junk yard but if u want take too machine shop complete head work about 250-325 but first just have the junk yards heads checked if bad take back with your findings in writing from shop they will replace them no charge 75 % of the time there okay.

^ spam?

No gym for home, work out floor with 30, but is it for 20 like 30 lb when you no lift it to be for men, for 30 lbs instead? or half is 10 for 20 pounds?

UMM HOW i word this... ok u take 20 lbs no lifting for 30lb if guy, so divide 2 u dont sit, u get 10 but for guy it no 30, so 20 would be for guy if u werent a girl ?

THEN WHO WAS PHONE

I cant stop laughing!! Due to recent happeneings with the car and life, its a much needed laugh.

This is not like an LS1 where most of the bolts are torque to yeild and can only be used once. These bolts are torqued very little (with exception of flywheel and front hub) and can be reused repeatedly without issue. And, mazda RAPES on parts, even the cost of bolts and nuts. I mean, each of the little bolts is probably a dollar or 2. The big ones like tension bolts, no telling how much those things are.

Basically there are plenty of areas to focus your attention on regarding part replacement with this engine, and the bolts aren't one of them.

Great work RR ... Thanks for helping me get my learn on.

:( I stripped a nut coming off of the exhaust manifold. and I don't know what to do!

Help me get my learrn on.

How did you strip it? Try using a stud extractor. If you stripped the hole get a tap and die set.

I just used the 14mm socket and the edges of the nut are stripped. I CANNOT get it off. Does anybody sell those studs, and nuts? I couldn't find em on mazdatrix.

Dealer???? they shouldnt be that bad for price and use a wrench and or a universal w/ the socket it wont strip the nut and you can get it off better

GO to sears, buy a stud remover kit and that will take it off. Might try lubricating it beforehand or using a propane torch to heat the stud.

I have some of the studs and nuts laying around if you need, or you can buy them new individually from mazda...check with ray at malloy mazda, hmkparts@aol.com

Okay. I Used a BOSCH Bolt Extractor socket set to take the nut off. That socket+17 in Breaker bar=EASIEST thing I've done in my life.

Atta boy.

Mazda says that there is two different kinds of studs/nuts. One kind for the two in the rear and one kind for the other four. I just have to make time to go down there, and check em out.

They want $3 EACH per stud for the two. and $16 EACH for the other 4. I think I'll go with you, rr.

Thanks for the pics.

Great Thread Kevin, Thanks...

Got one of those cherry picker hoists years ago, great value and VERY handy, ever tried a 2 ton lift ?...

Notice the Oil Injector line Banjo Fittings are Brass, are ALL Series 1 Renesis brass??, I know there is only one Part Number listing...so I guess they are.

Series 2 EMOP line banjo's are alloy with No check or one way valve inside...I guess the Series 1's have to be brass because of the check valve inside banjo?

The six S2 lines are way shorter, each are different melded shape but only about 6 inches long each.

...

Hi,

does anyone have any ideas about how to pull a permanently stuck intake manifold?

I'm swapping the motor in a friends RX8.

I can't seem to figure out how to get a puller on it. I've also tried rigging up something with my portapower but I can't get a good hold on it anywhere and my expander attachment is broken.

I'm at a loss. Anybody have anything creative?

Thanks.

H

what? the manifold should not be stuck make sure you pulled every bolt off. I guarantee you are missing one.

If you have removed all of the bolts...the APV barrels may be so carboned up that the manifold won't pull out. DO NOT pull hard on it or you will break the mounting tabs off

Usually there will be some in/out movement with this though....so it should move a bit..otherwise look for a bolt :)

I had one like this on an engine I had...it took a lot of carb cleaner and time to carefully get it out

Otherwise you will need a new LIM :(

Thanks. I counted 6 bolts, I think. It's sitting in carb cleaner right now. And will probably stay that way until next weekend at this point.

The flywheel bolt is odd. It looks like a 55mm. Guess I'll have to chase down the snapon guy tomorrow for that one. And it's not staked or pinned or anything. Weird.

H

Its on with about 450 ft lbs and I used a 2 1/8" not sure if its 55 mm or 56mm

Thank you, sir! I sourced a Craftsman 2 1/8" socket from the local Sears store yesterday. It fits perfectly. My impact gun, on the other hand, was completely impotent.

I have a friend that owns every snapon tool ever made since he was sponsored by them for two race seasons. We'll see what he has up his sleeve. I want to take it off with an impact gun so I don't have to worry about holding the flywheel. And, I don't have this engine on a stand, either. I'm doing this bubba style. Well, not really. The full bubba would require to move it outside onto the front lawn. ;)

H

I bought the stand adapter from mazdatrix it was totally worth it. if you are just breaking it down to send to a builder than its not worth it.

This is how we got the rear nut off.

http://a4.sphotos.ak.fbcdn.net/hphot..._1607055_n.jpg

and this is how we got he front bolt off.

http://a6.sphotos.ak.fbcdn.net/hphot..._7207588_n.jpg

Yeah. The owner bought a Mazda crate motor. It's his wife's car.

factory use Loctite on the nut, so to break it easy , just heat the nut with propane torch, the nut ONLY, for maybe 3-5 minutes, then u can take it out easy.

Thats love right there.