ENGINE MECHANICAL

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1993-94 323 and 1994 MX3 1.6L (B6E), 1993-95 Protege 1.8L (BPD, BPE) and 1994 MX3 1.6L (B6-ZE) Engines

Properly relieve the fuel system pressure. Raise and safely support the vehicle, as necessary.
Disconnect the battery cables and remove the battery and the battery tray. Raise and safely support the vehicle.
Remove the splash shield(s) from under the vehicle and drain the engine and transaxle oil and the coolant.
Remove the air cleaner assembly and resonance chamber, including the air flow meter and all of the ducting. Remove the oil dipstick.
Remove the radiator hoses. If equipped with automatic transaxle, disconnect the oil cooler lines from the radiator. Disconnect the cooling fan and, if equipped, radiator switch electrical connectors and remove the radiator/cooling fan assembly.
Disconnect the throttle and the speedometer cable.
Label and disconnect the vacuum hoses and wiring.
Disconnect the fuel supply and return hoses and the heater hoses.
Disconnect the exhaust pipe from the manifold.
Without disconnecting the hydraulic hoses, remove the power steering pump and hang it from the body with wire.
Without disconnecting the refrigerant lines, remove the air conditioning compressor and hang it from the body with wire.
If equipped with manual transaxle, disconnect the clutch cable and shift control rod. If equipped with hydraulic clutch, remove the slave cylinder from the transaxle without disconnecting the hydraulic line.
If equipped with automatic transaxle, disconnect the shift control cable.
Remove the nuts and disconnect the tie rod ends from the steering knuckles. Disconnect the stabilizer bar from the lower control arms.
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.
Remove the engine mount nuts and the engine mount member bolts and nuts and remove the engine mount member.
NOTE: Be careful so the engine does not fall when removing the engine mount member.
Remove the pinch bolts from the steering knuckle and pry the control arm down to slip lower ball joint out of the knuckle.
If equipped, remove the bolts from the right side intermediate shaft support and, using a suitable prybar, pry the intermediate shaft from the transaxle. Insert a suitable prybar between the inner CV-joint and transaxle case and carefully pry the inner CV-joints out of the transaxle. Suspend the halfshafts with wire.
Remove the dynamic damper from the right side engine mount, if equipped. Remove the engine/transaxle mount nuts/bolts and right engine and, if equipped, left transaxle mounts. Carefully lift the engine/transaxle assembly from the vehicle.
Properly support the engine/transaxle assembly. Remove the intake manifold bracket, starter, torque converter nuts, stiffener, if equipped and No. 2 engine mount. Disconnect the throttle cable.
Remove the transaxle mounting bolts and separate the transaxle from the engine.
To install:
Attach the transaxle to the engine and install the transaxle-to-engine bolts. If equipped with automatic transaxle, install the torque converter nuts and tighten to 25-36 ft. lbs. (34-49 Nm).
Connect the throttle cable. Install the No. 2 engine mount, stiffener, if equipped, starter and intake manifold bracket.
On 2WD vehicles, proceed as follows:
1. Install the engine mount member and tighten the bolts/nuts to 47-66 ft. lbs. (64-89 Nm).
2. Carefully lower the engine/transaxle assembly into the engine compartment and align the engine mount bolts with the engine mount member mounting holes. Install the mount-to-mount member nuts and tighten to 27-38 ft. lbs. (37-52 Nm).
3. Install the right side engine mount. Tighten the mount-to-engine nut(s) to 54-76 ft. lbs. (74-103 Nm) on 1993 vehicles. Tighten the mount through-bolt to 49-69 ft. lbs. (67-93 Nm) on 1993 vehicles.
4. On 1993 vehicles, install the dynamic damper, to the right side mount and tighten to 41-59 ft. lbs. (55-80 Nm).
5. If equipped, install the left side transaxle mount. On 1993 vehicles, loosely install the mount-to-transaxle nuts and align the mount bracket holes with the body holes. Install the mount-to-body bolts and tighten, in sequence, to 32-45 ft. lbs. (43-61 Nm). Tighten the mount-to-transaxle nuts to 49-69 ft. lbs. (67-93 Nm).
Install new circlips on the inner CV-joint stub shafts and, if equipped, intermediate shaft. Grease the shaft splines and install the halfshaft/intermediate shaft into the transaxle.
If equipped, install the right intermediate shaft support bolts and tighten, in sequence, to 31-46 ft. lbs. (42-62 Nm).
Install the lower ball joint and torque the clamping bolt to 43 ft. lbs. (59 Nm). Install the tie rod ends and torque the nut to 42 ft. lbs. (57 Nm), then tighten as required to install a new cotter pin.
Attach the stabilizer bar and tighten the nuts so there is ³⁄₄ in. (19mm) of thread showing above the nut.
If equipped with manual transaxle, connect the extension bar and shift control rod. Connect the clutch cable or install the hydraulic slave cylinder, as necessary.
If equipped with automatic transaxle, connect the shift control cable.
Install a new gasket and connect the exhaust pipe to the manifold. Use new self-locking nuts and torque to 34 ft. lbs. (46 Nm).
Connect the wiring and all heater, fuel and vacuum hoses.
Install the air conditioner compressor and power steering pump, if equipped.
Install the radiator/cooling fan assembly and connect the radiator hoses and the necessary electrical connectors.
Connect the accelerator and speedometer cables.
Install the battery tray assembly and battery. Install the air cleaner and air flow meter assembly and all the ducting. Connect the air flow sensor connector.
Install the splash shield(s).
Fill the engine and the transaxle with the proper types and quantities of oil. Fill the cooling system.
Connect the negative battery cable, start the engine and check for leaks. Check the ignition timing and the idle speed. Check all fluid levels.

1995-97 Protege 1.5L (Z5D) and 1.8L (BPD) Engines

Relieve the fuel system pressure, and disconnect the battery cables.
Mark the position of the hood on its hinges, and remove the hood.
Drain the cooling system, engine oil and transaxle oil.
Slightly raise the vehicle and remove the front wheels.
Remove the upper and lower radiator hose and, on automatic transaxles (ATX) only, the oil cooler hose.
Disconnect the cooling fan motor connector, and remove the coolant reservoir pipe.
Remove the radiator bracket. Remove the radiator and cooling fan assembly.
Disconnect the oxygen sensor connector. Remove and discard the exhaust pipe-to-catalytic converter nuts.
Remove the exhaust support bolts. Remove and discard the exhaust pipe-to-exhaust manifold nuts and remove the exhaust pipe. Support the remaining exhaust system with mechanics wire.
Remove the exhaust manifold.
Remove the air cleaner assembly.
Remove the battery clamp, battery and battery tray.
Remove the coolant reservoir, and the battery duct bracket.
Remove the resonance chamber.
Disconnect the accelerator cable.
If equipped with an automatic transaxle, remove the throttle cable.
Remove the splash shield.
Remove the power steering belt shield and the power steering belt. Remove the power steering hose brackets from the cylinder head cover.
Remove the power steering belt adjuster and disconnect the power steering pressure switch connector. Remove the power steering pump and position aside, leaving the hoses connected.
If equipped, remove the A/C compressor and position aside, leaving the refrigerant lines attached. Support the compressor with suitable wire.
Label and disconnect the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator. Disconnect and label any remaining engine harness connectors.
Label, disconnect and plug the fuel lines at the fuel rail.
Disconnect the heater hoses.
Raise and safely support the vehicle. Attach suitable engine lifting equipment to the lifting eyes on the engine.
On manual transaxles (MTX), remove the bolts and clips from the clutch slave cylinder. Remove the slave cylinder with the hose still connected, and position it away from the transaxle.
On MTX, remove the extension bar nut and washer, then disengage the bar from the transaxle. Remove the transaxle control rod through-bolt and nut, then disengage the rod from the transaxle.
On ATX, disconnect the shift control cable from the transaxle.
Remove the stabilizer control link and the tie-rod end ball joint.
Remove the bolts and nuts from the lower arm ball joints, and pry the lower arms from the knuckles.
Separate the driveshafts and the joint shaft from the transaxle. Install transaxle plug tools T88C-7025-AH or equivalent, into the differential side gears.
NOTE: If the plugs are not installed, the differential side gears may become mispositioned. If the gears are. mispositioned, the differential may have to be removed to reposition them.
Remove the number one engine mount bracket.
Remove the transverse (engine mount) member,and the number 2 engine mount bracket nuts.
Remove the number three and four engine mount brackets.
Lower the vehicle. Slowly lift the engine and transaxle assembly as a unit out of the vehicle. Keep the engine from swinging or bumping into components in the engine compartment.
On ATX, remove the torque converter-to-flexplate nuts.
Remove the engine-to-transaxle bolts and the transaxle-to-engine mounting bolts.
Separate the engine from the transaxle.
On MTX, remove the clutch assembly, flywheel and crankshaft rear cover plate. On ATX, remove the flexplate and throttle cable.
Place the engine on a workstand.
To install:
Remove the engine from the workstand.
On ATX, remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
On MTX, install the crankshaft rear cover plate and tighten the bolt to 88 inch lbs. (10 Nm). Install the flywheel and clutch assembly.
On ATX:
1. Install the transaxle-to-engine bolts and tighten the mounting bolts to 41-59 ft. lbs. (55-80 Nm).
2. Install the torque converter to the flexplate and tighten the nuts to 26-36 ft. lbs. (35-49 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
On MTX, install the transaxle mounting bolts and tighten the bolts to 48-65 ft. lbs. (64-89 Nm).
Hoist the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes. Install the engine mounts.
Install the transverse member. Tighten the mounting bolts to 50-65 ft. lbs. (67-89 Nm), and the nuts (including engine mount number two) to 28-38 ft. lbs. (38-51 Nm).
Apply grease to the end of the joint shaft and the end of the driveshaft.
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joint to the knuckle, and tighten the through-bolt to 32-43 ft. lbs. (44-58 Nm).
Install the tie-rod end to the knuckle, and tighten to 32-41 ft. lbs. (43-56 Nm). Install a new cotter pin.
Install the stabilizer control link, and tighten to 32-44 ft. lbs. (44-60 Nm).
On MTX, install the clutch slave cylinder. and tighten the bolts to 14-18 ft. lbs. (19-25 Nm).
On MTX, connect the extension bar to the transaxle with the washer and nut. Tighten the nut to 38 ft. lbs. (51 Nm). Connect the control rod to the transaxle with the through-bolt and nut. Tighten the through-bolt to 12-16 ft. lbs. (16-22 Nm).
On ATX, install the selector cable, and tighten the mounting nut to 12-16 ft. lbs. (16-22 Nm).
Connect the heater hoses.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
If equipped, install the A/C compressor on the mounting bracket and tighten the bolts to 26 ft. lbs. (35 Nm).
Install the alternator belt and adjust the tension. Tighten the alternator upper mounting bolt to 18 ft. lbs. (25 Nm).
Raise and safely support the vehicle. Tighten the alternator through-bolt to 38 ft. lbs. (52 Nm).
Install the splash shields and lower the vehicle.
Loosely install the power steering pump through-bolt and lockbolt. Connect the power steering switch connector and install the power steering belt.
Adjust the power steering belt tension, then tighten the through-bolt to 38 ft. lbs. (51 Nm) and the lockbolt to 34 ft. lbs. (46 Nm).
Install the power steering pump belt shield and tighten the bolts to 86 inch lbs. (9 Nm). Install the power steering hose brackets to the cylinder head cover and tighten the bolts to 88 inch lbs. (10 Nm).
Install and adjust the accelerator and throttle cables.
Install the resonance chamber.
Install the battery duct bracket and coolant reservoir.
Install the battery tray, clamp and battery.
Install the air cleaner assembly.
Install the exhaust manifold.
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 24-33 ft. lbs. (32-46 Nm). Attach the exhaust pipe support bracket to the engine and tighten the bolts to 24-33 ft. lbs. (32-46 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts, and tighten to 24-33 ft. lbs. (32-46 Nm). Connect the oxygen sensor connector and lower the vehicle.
Install the radiator and coolant fan.
Connect the radiator hoses, coolant reservoir hose and the cooling fan motor connector. On ATX, connect the oil cooler lines.
Install the shroud upper panel.
Install the front wheels.
Install the hood, aligning the marks that were made during removal.
Connect the battery cables.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.
Inspect the ignition timing and idle speed.

1995 MX3 1.6L (B6-ZE), 1994-95 MX3 1.8L (K8) and 1993-97 626 and MX6 2.5L (KL) Engines

Relieve the fuel system pressure and disconnect the battery cables. Remove the battery and battery tray.
Mark the position of the hood on its hinges and remove the hood.
Drain the cooling system, engine oil and transaxle oil.
Slightly raise the vehicle and remove the front wheels.
Remove the splash shield.
Remove the fresh air dust, air cleaner assembly and coolant reservoir.
Disconnect the accelerator cable.
Remove the upper and lower radiator hose and, on automatic transaxles (ATX) only, the oil cooler hose.
Disconnect the cooling fan motor connector, and remove the coolant reservoir pipe.
Remove the radiator bracket. Remove the radiator and cooling fan assembly.
Loosen the locknut and adjuster bolt on the power steering belt tensioner and remove the belt. Remove the 3 power steering pump mounting bolts working through the pulley holes.
Remove the rear bracket bolt from the power steering pump and secure the pump aside with mechanics wire.
If equipped, remove the 4 A/C compressor mounting bolts and secure the compressor aside with mechanics wire, leaving the refrigerant lines attached. Do not let the compressor hang by the refrigerant lines.
Remove the power steering hose bracket from the pump. Loosen the alternator belt tensioner locknut and adjuster bolt and remove the belt.
If equipped, disconnect the cruise control actuator electrical connector. Remove the 2 nuts from the actuator bracket and position the actuator and bracket aside.
On ATX, disconnect the shift linkage from the transaxle.
Label and disconnect the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator. Label and disconnect any remaining engine harness connectors.
Label, disconnect and plug the fuel lines at the fuel rail.
If equipped, disconnect the cruise control vacuum hose from the back right-hand side of the intake manifold.
Disconnect the vacuum line connecting the evaporative canister and the metal EGR vacuum line.
Disconnect the power booster vacuum line from the back left-hand side of the intake manifold.
Disconnect the heater hoses and remove the upper starter mounting bolts.
Raise and safely support the vehicle. Attach suitable engine lifting equipment to the lifting eyes on the engine.
On the 2.5L engine, remove the fuel filter and bracket.
On manual transaxles (MTX), remove the bolts and clips from the clutch slave cylinder. Remove the slave cylinder with the hose still connected, and position it away from the transaxle.
Remove the transverse member.
Disconnect the oxygen sensor connector. Remove and discard the exhaust pipe-to-catalytic converter nuts.
Remove the exhaust support bolts. Remove and discard the exhaust pipe-to-exhaust manifold nuts and remove the exhaust pipe. Support the remaining exhaust system with mechanics wire.
On MTX, remove the extension bar nut and washer, then disengage the bar from the transaxle. Remove the transaxle shift linkage through-bolt and nut, then disengage the linkage from the transaxle.
Remove the stabilizer control link and the tie-rod end ball joint.
Remove the bolts and nuts from the lower arm ball joints, and pry the lower arms from the knuckles.
Separate the driveshafts and the joint shaft from the transaxle. Install transaxle plug tools T88C-7025-AH or equivalent, into the differential side gears.
NOTE: If the plugs are not installed, the differential side gears may become mispositioned. If the gears are is positioned, the differential may have to be removed to reposition them.
On the 1.6L B6E-ZE) engine remove the transverse (engine mount) member,and the number 2 engine mount nuts. Remove the number one, three and four engine mounts.
On the 1.8L (K8) engine, remove the number three and four engine mounts. Remove the crossmember. Remove the nuts from the engine mount number two.
On the 2.5L engine, remove the fuse box, engine mounts Nos. 1, 3 and 4. Remove the crossmember, then remove the nuts from the engine mount No. 2, and remove engine mount No. 5.
Lower the vehicle. Slowly lift the engine and transaxle assembly as a unit out of the vehicle. Keep the engine from swinging or bumping into components in the engine compartment.
Remove the starter. Remove the engine mount number two.
On ATX, remove the throttle cable and torque converter-to-flexplate nuts.
Remove the engine-to-transaxle bolts and the transaxle-to-engine mounting bolts.
Separate the engine from the transaxle.
On MTX, remove the clutch assembly, flywheel and crankshaft rear cover plate. On ATX, remove the flexplate.
Place the engine on a workstand.
To install:

1.6L (B6-ZE) Engine

Remove the engine from the workstand.
On ATX, remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
On MTX, install the crankshaft rear cover plate and tighten the bolt to 88 inch lbs. (10 Nm). Install the flywheel and clutch assembly.
On ATX:
1. Install the transaxle-to-engine bolts and tighten mounting bolts A to 41-59t. lbs. (55-80m).
2. Install the torque converter to the flexplate and tighten the nuts to 26-36 ft. lbs. (35-49 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
3. Install the remaining transaxle-to-engine mounting bolts. Tighten mounting bolt B to 28-38 ft. lbs. (38-51 Nm).
On MTX, install the transaxle mounting bolts and tighten bolts A to 48-65 ft. lbs. (64-89 Nm), and bolts B to 28-38 ft. lbs. (38-51 Nm).
Install engine mount number two onto the transaxle and tighten to 28-38 ft. lbs. (38-51 Nm).
Install the starter and tighten the bolts to 28-38 ft. lbs. (38-51 Nm). Install the intake manifold support bracket and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Suspend the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes.Install the engine mounts.
Install a new clip on the joint shaft and install the shaft. Tighten the three mounting bolts to 32-45 ft. lbs. (43-61 Nm). Apply grease to the end of the joint shaft and the end of the driveshaft.
Install the transverse member. Tighten the mounting bolts to 48-65 ft. lbs. (64-89 Nm), and the nuts (including engine mount number two) to 28-38 ft. lbs. (38-51 Nm).
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joint to the knuckle, and tighten the through-bolt to 32-43 ft. lbs. (44-58 Nm).
Install the tie-rod end to the knuckle, and tighten to 32-41 ft. lbs. (43-56 Nm). Install a new cotter pin.
Install the stabilizer control link, and tighten to 32-44 ft. lbs. (44-60 Nm).
On MTX, connect the extension bar to the transaxle with the washer and nut. Tighten the nut to 38 ft. lbs. (51 Nm). Connect the shift linkage to the transaxle with the through-bolt and nut. Tighten the through-bolt to 18 ft. lbs. (25 Nm).
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 24-33 ft. lbs. (32-46 Nm). Attach the exhaust pipe support bracket to the engine and tighten the bolts to 24-33 ft. lbs. (32-46 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts, and tighten to 24-33 ft. lbs. (32-46 Nm). Connect the oxygen sensor connector and lower the vehicle.
On MTX, install the clutch slave cylinder. and tighten the bolts to 12-16 ft. lbs. (16-22 Nm).
Connect the heater hoses. If equipped, connect the cruise control vacuum line to the back right-hand side of the intake manifold.
Connect the vacuum line connecting the evaporative canister to the metal EGR vacuum line. Connect the power brake booster vacuum line to the back left-hand side of the intake manifold.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
If equipped, install the A/C compressor on the mounting bracket and tighten the bolts to 26 ft. lbs. (35 Nm).
Install the alternator belt and adjust the tension. Tighten the alternator upper mounting bolt to 18 ft. lbs. (25 Nm).
Raise and safely support the vehicle. Tighten the alternator through-bolt to 38 ft. lbs. (52 Nm).
Install the splash shields and lower the vehicle.
Loosely install the power steering pump through-bolt and lockbolt. Connect the power steering switch connector and install the power steering belt.
Adjust the power steering belt tension, then tighten the through-bolt to 38 ft. lbs. (51 Nm) and the lockbolt to 34 ft. lbs. (46 Nm).
Install the power steering pump belt shield and tighten the bolts to 86 inch lbs. (9 Nm). Install the power steering hose brackets to the cylinder head cover and tighten the bolts to 88 inch lbs. (10 Nm).
Install the radiator and coolant fan.
Connect the radiator hoses, coolant reservoir hose and the cooling fan motor connector. On ATX, connect the oil cooler lines.
Install and adjust the accelerator cable. Install the air cleaner assembly.
Install the shroud upper panel and the fresh air duct.
Install the battery tray and battery. Connect the battery cables.
Install the front wheels.
Install the hood, aligning the marks that were made during removal.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.

1.8L (K8) Engine

Remove the engine from the workstand.
On ATX, remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
On MTX, install the crankshaft rear cover plate and tighten the bolt to 88 inch lbs. (10 Nm). Install the flywheel and clutch assembly.
On ATX:
1. Install the transaxle-to-engine bolts and tighten the mounting bolts to 50-73 ft. lbs. (68-99 Nm).
2. Install the torque converter to the flexplate and tighten the nuts to 28-45 ft. lbs. (38-60 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
On MTX, install the transaxle mounting bolts and tighten to 50-73 ft. lbs. (68-99 Nm).
Install engine mount number two onto the transaxle and tighten to 28-38 ft. lbs. (38-51 Nm).
On ATX, install the throttle cable.
Install the starter and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Suspend the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes.
Install the crossmember, and tighten the four mounting bolts to 48-65 ft. lbs. (64-89 Nm). Install the engine mounts.
Install a new clip on the joint shaft and install the shaft. Tighten the three mounting bolts to 32-45 ft. lbs. (43-61 Nm). Apply grease to the end of the joint shaft and the end of the driveshaft.
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joints to the knuckles, and tighten the through-bolt to 32-43 ft. lbs. (44-58 Nm).
Install the tie-rod end to the knuckle, and tighten to 32-41 ft. lbs. (43-56 Nm). Install a new cotter pin.
Install the stabilizer control link, and tighten to 32-44 ft. lbs. (44-60 Nm).
On MTX, connect the extension bar to the transaxle with the washer and nut. Tighten the nut to 24-33 ft. lbs. (32-46 Nm). Connect the shift linkage to the transaxle with the through-bolt and nut. Tighten the through-bolt to 12-16 ft. lbs. (16-22 Nm).
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 48-65 ft. lbs. (64-89 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts and tighten to 30-40 ft. lbs. (41-54 Nm). Connect the oxygen sensor connector and lower the vehicle.
Install the transverse member and tighten the four mounting bolts to 69-93 ft. lbs. (94-126 Nm).
On MTX, install the clutch slave cylinder. and tighten the bolts to 12-16 ft. lbs. (16-22 Nm).
If equipped, align the cruise control actuator and install the nuts. Connect the actuator electrical connector.
Connect the heater hoses. If equipped, connect the cruise control vacuum line to the back right-hand side of the intake manifold.
Connect the vacuum line connecting the evaporative canister to the metal EGR vacuum line. Connect the power brake booster vacuum line to the back left-hand side of the intake manifold.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
If equipped, install the A/C compressor on the mounting bracket and tighten the bolts to 18-26 ft. lbs. (24-35 Nm).
Install the alternator belt and adjust the tension. Tighten the alternator upper mounting bolt to 18 ft. lbs. (25 Nm).
Raise and safely support the vehicle. Tighten the alternator through-bolt to 38 ft. lbs. (52 Nm).
Install the splash shields and lower the vehicle.
Align the power steering pump and install the rear bracket bolt. Tighten to 34 ft. lbs. (46 Nm). Install the power steering hose bracket bolt and tighten to 34 ft. lbs. (46 Nm).
Install the 3 power steering pump bolts through the pulley and tighten to 34 ft. lbs. (46 Nm). Install the power steering belt and adjust the tension.
Install the radiator and coolant fan.
Connect the radiator hoses, coolant reservoir hose. Connect the cooling fan motor connector. On ATX, connect the oil cooler lines.
Install and adjust the accelerator cable. Install the air cleaner, fresh air ducts and coolant reservoir.
Install the battery tray and battery. Connect the battery cables.
Install the front wheels.
Install the hood, aligning the marks that were made during removal.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.

1993-97 626 and MX6 2.5L (KL) Engine

Remove the engine from the workstand.
On ATX, remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
On MTX, install the crankshaft rear cover plate and tighten the bolt to 88 inch lbs. (10 Nm). Install the flywheel and clutch assembly.
On ATX:
1. Install the transaxle-to-engine bolts and tighten the mounting bolts to 50-73 ft. lbs. (68-99 Nm).
2. Install the torque converter to the flexplate and tighten the nuts to 28-45 ft. lbs. (38-60 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
On MTX, install the transaxle mounting bolts and tighten to 50-73 ft. lbs. (68-99 Nm).
Install engine mount number two onto the transaxle and tighten to 28-38 ft. lbs. (38-51 Nm).
Install the starter and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Suspend the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes.
Install the crossmember, and tighten the four mounting bolts to 50-68 ft. lbs. (67-93 Nm). Install the engine mounts.
Install the fuse box.
Install a new clip on the joint shaft and install the shaft. Tighten the three mounting bolts to 32-45 ft. lbs. (43-61 Nm). Apply grease to the end of the joint shaft and the end of the driveshaft.
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joints to the knuckles, and tighten the through-bolt to 32-43 ft. lbs. (44-58 Nm).
Install the tie-rod end to the knuckle, and tighten to 32-41 ft. lbs. (43-56 Nm). Install a new cotter pin.
Install the stabilizer control link, and tighten to 32-44 ft. lbs. (44-60 Nm).
On MTX, connect the extension bar to the transaxle with the washer and nut. Tighten the nut to 24-33 ft. lbs. (32-46 Nm). Connect the shift linkage to the transaxle with the through-bolt and nut. Tighten the through-bolt to 12-16 ft. lbs. (16-22 Nm).
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 48-65 ft. lbs. (64-89 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts and tighten to 28-38 ft. lbs. (38-51 Nm). Connect the oxygen sensor connector and lower the vehicle.
Install the transverse member and tighten the six mounting bolts to 69-93 ft. lbs. (94-126 Nm).
On MTX, install the clutch slave cylinder. and tighten the bolts to 12-16 ft. lbs. (16-22 Nm).
If equipped, align the cruise control actuator and install the nuts. Connect the actuator electrical connector.
Install the fuel filter.
Connect the heater hoses. If equipped, connect the cruise control vacuum line to the back right-hand side of the intake manifold.
Connect the vacuum line connecting the evaporative canister to the metal EGR vacuum line. Connect the power brake booster vacuum line to the back left-hand side of the intake manifold.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
If equipped, install the A/C compressor on the mounting bracket and tighten the bolts to 18-26 ft. lbs. (24-35 Nm).
Install the alternator belt and adjust the tension. Tighten the alternator upper mounting bolt to 18 ft. lbs. (25 Nm).
Raise and safely support the vehicle. Tighten the alternator through-bolt to 38 ft. lbs. (52 Nm).
Install the splash shields and lower the vehicle.
Align the power steering pump and install the rear bracket bolt. Tighten to 34 ft. lbs. (46 Nm). Install the power steering hose bracket bolt and tighten to 34 ft. lbs. (46 Nm).
Install the three power steering pump bolts through the pulley and tighten to 34 ft. lbs. (46 Nm). Install the power steering belt and adjust the tension.
Install the radiator and coolant fan.
Connect the radiator hoses, coolant reservoir hose. Connect the condenser and cooling fan motor connectors. On ATX, connect the oil cooler lines.
Install and adjust the accelerator cable. Install the air cleaner, fresh air ducts and air hose.
Install the battery tray and battery. Connect the battery cables.
Install the front wheels.
Install the hood, aligning the marks that were made during removal.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.

626 and MX6 2.0L (FS) Engines

Relieve the fuel system pressure and disconnect the battery cables. Remove the battery and battery tray.
Mark the position of the hood on its hinges and remove the hood.
Drain the cooling system, engine oil and transaxle oil.
Slightly raise the vehicle and remove the front wheels.
Remove the splash shield.
Remove the fresh air dust, air cleaner assembly, air hose and resonance chamber.
Label and disconnect the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
Disconnect the accelerator cable.
Remove the fuel filter.
Remove the upper and lower radiator hose and, on automatic transaxles (ATX) only, the oil cooler hose.
Disconnect the cooling fan motor connector, and remove the coolant reservoir pipe.
Remove the radiator bracket. Remove the radiator and cooling fan assembly.
Remove the power steering belt shield and the power steering belt. Remove the power steering hose brackets from the cylinder head cover.
Remove the power steering belt adjuster and disconnect the power steering pressure switch connector. Remove the power steering pump and position aside, leaving the hoses connected.
If equipped, remove the A/C compressor and position aside, leaving the refrigerant lines attached. Support the compressor with suitable wire.
Loosen the alternator adjusting bolt, remove the upper mounting bolt and remove the alternator belt.
Disconnect and label any remaining engine harness connectors.
Label, disconnect and plug the fuel lines at the fuel rail.
If equipped, disconnect the cruise control vacuum hose from the back right-hand side of the intake manifold.
Disconnect the vacuum line connecting the evaporative canister and the metal EGR vacuum line.
Disconnect the power booster vacuum line from the back left-hand side of the intake manifold.
Disconnect the heater hoses and remove the upper starter mounting bolts. Raise and safely support the vehicle. Attach suitable engine lifting equipment to the lifting eyes on the engine.
On manual transaxles (MTX), remove the bolts and clips from the clutch slave cylinder. Remove the slave cylinder with the hose still connected, and position it away from the transaxle.
On ATX, disconnect the shift control cable from the transaxle.
Remove the transverse member, the No. 5 engine mount rubber and the No. 2 engine mount nuts.
Remove the crossmember.
Disconnect the oxygen sensor connector. Remove and discard the exhaust pipe-to-catalytic converter nuts.
Remove the exhaust support bolts. Remove and discard the exhaust pipe-to-exhaust manifold nuts and remove the exhaust pipe. Support the remaining exhaust system with mechanics wire.
On MTX, remove the extension bar nut and washer, then disengage the bar from the transaxle. Remove the transaxle shift linkage through-bolt and nut, then disengage the linkage from the transaxle.
Remove the stabilizer control link and the tie-rod end ball joint.
Remove the bolts and nuts from the lower arm ball joints, and pry the lower arms from the knuckles.
Separate the driveshafts and the joint shaft from the transaxle. Install transaxle plug tools T88C-7025-AH or equivalent, into the differential side gears.
NOTE: If the plugs are not installed, the differential side gears may become mispositioned. If the gears are mispositioned, the differential may have to be removed to reposition them.
Remove the number one, three and four engine mounts.
Lower the vehicle. Slowly lift the engine and transaxle assembly as a unit out of the vehicle. Keep the engine from swinging or bumping into components in the engine compartment.
Remove the starter and the intake manifold support bracket. Remove the engine mount number two.
On ATX, remove the torque converter-to-flexplate nuts.
Remove the engine-to-transaxle bolts and the transaxle-to-engine mounting bolts.
Separate the engine from the transaxle.
On MTX, remove the clutch assembly, flywheel and crankshaft rear cover plate. On ATX, remove the flexplate.
Place the engine on a workstand.
To install:
Remove the engine from the workstand.
On ATX, remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
On MTX, install the crankshaft rear cover plate and tighten the bolt to 88 inch lbs. (10 Nm). Install the flywheel and clutch assembly.
On ATX:
1. Install the transaxle-to-engine bolts and tighten mounting bolts A to 66-86 ft. lbs. (90-116 Nm).
2. Install the torque converter to the flexplate and tighten the nuts to 21-33 ft. lbs. (28-46 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
3. Install the remaining transaxle-to-engine mounting bolts. Tighten mounting bolt B to 28-38 ft. lbs. (38-51 Nm) and mounting bolt C to 14-18 ft. lbs. (19-25 Nm).
On MTX, install the transaxle mounting bolts and tighten to 66-86 ft. lbs. (90-116 Nm).
Install engine mount number two onto the transaxle and tighten to 32-44 ft. lbs. (44-60 Nm).
Install the starter and tighten the bolts to 28-38 ft. lbs. (38-51 Nm). Install the intake manifold support bracket and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Suspend the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes.Install the engine mounts.
Install a new clip on the joint shaft and install the shaft. Tighten the three mounting bolts to 32-45 ft. lbs. (43-61 Nm). Apply grease to the end of the joint shaft and the end of the driveshaft.
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joint to the knuckle, and tighten the through-bolt to 28-41 ft. lbs. (35-56 Nm).
Install the tie-rod end to the knuckle, and tighten to 24-32 ft. lbs. (32-44 Nm). Install a new cotter pin.
Install the stabilizer control link, and tighten to 27-39 ft. lbs. (37-53 Nm).
On MTX, connect the extension bar to the transaxle with the washer and nut. Tighten the nut to 38 ft. lbs. (51 Nm). Connect the shift linkage to the transaxle with the through-bolt and nut. Tighten the through-bolt to 18 ft. lbs. (25 Nm).
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 28-38 ft. lbs. (38-51 Nm). Attach the exhaust pipe support bracket to the engine and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts and tighten to 28-38 ft. lbs. (38-51 Nm). Connect the oxygen sensor connector and lower the vehicle.
Install the crossmember, and tighten the six mounting bolts to 69-97 ft. lbs. (94-131 Nm).
On MTX, install the clutch slave cylinder. and tighten the bolts to 12-16 ft. lbs. (16-22 Nm).
Connect the heater hoses. If equipped, connect the cruise control vacuum line to the back right-hand side of the intake manifold.
Connect the vacuum line connecting the evaporative canister to the metal EGR vacuum line. Connect the power brake booster vacuum line to the back left-hand side of the intake manifold.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
If equipped, install the A/C compressor on the mounting bracket and tighten the bolts to 26 ft. lbs. (35 Nm).
Install the alternator belt and adjust the tension. Tighten the alternator upper mounting bolt to 18 ft. lbs. (25 Nm).
Raise and safely support the vehicle. Tighten the alternator through-bolt to 38 ft. lbs. (52 Nm).
Install the splash shields and lower the vehicle.
Loosely install the power steering pump through-bolt and lockbolt. Connect the power steering switch connector and install the power steering belt.
Adjust the power steering belt tension, then tighten the through-bolt to 45 ft. lbs. (61 Nm) and the lockbolt to 34 ft. lbs. (46 Nm).
Install the power steering pump belt shield and tighten the bolts to 86 inch lbs. (9 Nm). Install the power steering hose brackets to the cylinder head cover and tighten the bolts to 88 inch lbs. (10 Nm).
Install the radiator and coolant fan.
Connect the radiator hoses, coolant reservoir hose and the cooling fan motor connector. On ATX, connect the oil cooler lines.
Install the fuel filter.
Install and adjust the accelerator cable. Install the air cleaner, air ducts and resonance chamber.
Install the battery tray and battery. Connect the battery cables.
Install the front wheels.
Install the hood, aligning the marks that were made during removal.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.

1993-95 929 3.0L (JE-ZE) Engines

Properly relieve the fuel system pressure. Disconnect the negative battery cable.
Mark the position of the hood on the hinges and remove the hood.
Remove the air cleaner assembly and the air ducts.
Remove the battery and battery tray.
Raise and safely support the vehicle. Remove the front wheels and splash shield.
Drain the cooling system, and the engine and transmission oil.
Remove the cooling fan and fan shroud.
Disconnect the radiator hoses and transmission cooler lines, and remove the radiator.
Remove the accessory drive belts.
Remove the A/C compressor and position aside, leaving the refrigerant lines attached.
Remove the alternator.
Remove the power steering pump pulley, using holder tool 49-W023-585A or equivalent, to hold the pulley while the nut is removed. Remove the power steering pump and position aside, leaving the hoses attached.
Disconnect the accelerator cable.
Label and disconnect the engine electrical harness, vacuum hoses, heater hoses and fuel lines.
Remove the dynamic chamber (upper intake manifold) and throttle body assembly.
Disconnect the exhaust pipes from the exhaust manifolds.
Remove the engine mount nuts.
Remove the starter, and disconnect the transmission from the engine.
Attach suitable lifting equipment to the engine. Carefully remove the engine from the vehicle and position on a workstand.
To install:
Carefully lower the engine into the engine compartment. Loosely install the engine mount nuts.
Connect the transmission. After the transmission and engine are bolted together, tighten the engine mount nuts to 36 ft. lbs. (49 Nm).
Install the starter.
Using new gaskets, connect the exhaust pipes to the exhaust manifolds. Tighten the nuts to 34 ft. lbs. (46 Nm).
Connect the electrical connectors, vacuum hoses, heater hoses and fuel lines.
Use a new gasket and install the dynamic chamber (upper intake manifold) and throttle body assembly. Tighten the bolts to 19 ft. lbs. (25 Nm).
Connect the accelerator cable, and the electrical connectors and hoses to the upper intake manifold and throttle body assembly.
Install the power steering pump, and tighten the mounting bolts to 34 ft. lbs. (46 Nm). Install the pump pulley, and tighten the nut to 43 ft. lbs. (59 Nm).
Install the alternator, and tighten the mounting bolts to 38 ft. lbs. (52 Nm).
Install the A/C compressor, and tighten the mounting bolts to 38 ft. lbs. (52 Nm).
Install the accessory drive belts and adjust the belt tension.
Install the radiator and tighten the mounting bolts to 19 ft. lbs. (26 Nm). Connect the radiator hoses and the transmission oil cooler lines.
Install the cooling fan and shroud.
Install the air cleaner assembly and ducts. Install the battery tray and battery.
Install the splash shield and wheels, and lower the vehicle.
Install the hood, aligning the marks that were made during removal.
Connect the battery cables. Fill the engine and transmission with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks.
Check the ignition timing and idle speed. Check all fluid levels and road test the vehicle for proper operation.

1995-97 Millenia 2.3L (KJS) Engines

Relieve the fuel system pressure, and disconnect the battery cables.
Mark the position of the hood on its hinges and remove the hood.
Drain the cooling system, engine oil and transaxle oil.
Slightly raise the vehicle and remove the front wheels.
Remove the dynamic chamber cover.
Remove the splash shields.
Remove the charge air cooler air duct.
Remove the air cleaner assembly and resonator.
Remove the battery clamp, battery and battery tray.
Remove the battery carrier and duct.
Remove the air cleaner air duct.
Disconnect the accelerator cable.
Remove the charge air cooler from the back of the engine.
Remove the dust cover from the drive belt.
Remove the drive belts.
Remove the crankshaft pulley.
Remove the vacuum pump pulley using a hexagon wrench to hold the pulley. Remove the left-handed thread mounting nut.
Remove the four A/C compressor mounting bolts, and secure the compressor aside with mechanics wire, leaving the refrigerant lines attached. Do not let the compressor hang by the refrigerant lines.
Remove the power steering pump pulley. Remove the power steering pump and secure the pump aside with mechanics wire.
Remove the front charge air cooler.
Remove the front radiator grill.
Remove the upper seal board (radiator bracket).
Remove the coolant reservoir and hose.
Disconnect the condenser and cooling fan motor connectors.
Remove the condenser and cooling fan motor assemblies.
Remove and plug the the oil cooler hose.
Remove the upper and lower radiator hoses.
Remove the radiator brackets.
Remove the radiator.
Disconnect the shift linkage from the transaxle.
Label and disconnect the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator. Label and disconnect any remaining engine harness connectors.
Label, disconnect and plug the fuel lines at the fuel rail.
Disconnect the heater hoses.
Raise and safely support the vehicle. Attach suitable engine lifting equipment to the lifting eyes on the engine.
Disconnect the oxygen sensor connector. Remove and discard the exhaust pipe-to-catalytic converter nuts.
Remove the exhaust support bolts. Remove and discard the exhaust pipe-to-exhaust manifold nuts and remove the exhaust pipe. Support the remaining exhaust system with mechanics wire.
Remove the upper lateral link link ball joint.
Remove the bolts and nuts from the lower arm ball joints, and pry the lower arms from the knuckles.
Separate the driveshafts and the joint shaft from the transaxle. Install transaxle plug tools T88C-7025-AH or equivalent, into the differential side gears.
NOTE: If the plugs are not installed, the differential side gears may become mispositioned. If the gears are mispositioned, the differential may have to be removed to reposition them.
Remove the number one engine mount bracket.
Remove the crossmember. Remove the nuts from the engine mount number two.
Remove engine mount number four bracket.
Remove engine mount number three sub-bracket.
Lower the vehicle. Slowly lift the engine and transaxle assembly as a unit out of the vehicle. Keep the engine from swinging or bumping into components in the engine compartment.
Remove the starter. Remove the engine mount number two.
Remove the torque converter-to-flexplate nuts.
Remove the engine-to-transaxle bolts and the transaxle-to-engine mounting bolts.
Separate the engine from the transaxle.
Remove the flexplate.
Place the engine on a workstand.
To install:
Remove the engine from the workstand.
Remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
Install the transaxle-to-engine bolts and tighten the mounting bolts to 50-73 ft. lbs. (68-99 Nm).
Install the torque converter to the flexplate and tighten the nuts to 28-45 ft. lbs. (38-60 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
Install engine mount number two onto the transaxle and tighten to 28-38 ft. lbs. (38-51 Nm).
Install the starter and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Suspend the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes.
Install the crossmember, and tighten the three mounting bolts to 50-68 ft. lbs. (67-93 Nm).
Install the engine mounts.
Install a new clip on the joint shaft and install the shaft. Tighten the three mounting bolts to 32-45 ft. lbs. (43-61 Nm). Apply grease to the end of the joint shaft and the end of the driveshaft.
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joint to the knuckle, and tighten the through-bolt to 58-86 ft. lbs. (79-116 Nm).
Install the upper lateral link ball joint using a new cotter pin, and tighten to 41-59 ft. lbs. (55-80 Nm).
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 28-38 ft. lbs. (38-51 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts and tighten to 28-38 ft. lbs. (38-51 Nm). Connect the oxygen sensor connector and lower the vehicle.
Connect the heater hoses.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
Connect the shift linkage to the transaxle.
Install the radiator.
Install the radiator brackets. Tighten the mounting bolts to 70-95 inch lbs. (8-11 Nm).
Connect the radiator hoses.
Unplug and connect the oil cooler lines.
Install the condenser and cooling fan motor assemblies.
Connect the condenser and cooling fan motor connectors.
Install the coolant reservoir and hose.
Install the upper seal board.
Install the front radiator grill.
Install the front charge air cooler, using new O-rings. Tighten the mounting bolts to 14-18 ft. lbs. (19-25 Nm).
Position the power steering pump and install the mounting bolts. Install the pulley and tighten the mounting nut to 37-43 ft. lbs. (50-58 Nm).
Position the A/C compressor and install the mounting bolts.
Position the vacuum pump pulley. Tighten the left-hand thread mounting nut to 73-101 ft. lbs. (99-137 Nm).
Install the crankshaft pulley. Tighten the center mounting bolt to 116-122 ft. lbs. (157-166 Nm), and the surrounding mounting bolts to 19-22 ft. lbs. (26-30 Nm).
Install the drive belts.
Install the dust cover for the drive belt.
Install the rear charge air cooler, using new O-rings. Tighten the mounting bolts to 14-18 ft. lbs. (19-25 Nm).
Install and adjust the accelerator cable.
Install the air cleaner air duct.
Install the battery duct and carrier.
Install the battery tray, battery and battery clamp.
Install the resonator and air cleaner assembly.
Install the charge air cooler air duct.
Install the dynamic chamber cover.
Install the splash shields and front wheels.
Install the hood, aligning the marks that were made during removal.
Connect the battery cables.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.

1995-97 Millenia 2.5L (KLD) Engine

Relieve the fuel system pressure, and disconnect the battery cables.
Remove the battery clamp, battery and battery tray.
Remove the battery carrier and duct.
Mark the position of the hood on its hinges and remove the hood.
Drain the cooling system, engine oil and transaxle oil.
Slightly raise the vehicle and remove the front wheels.
Remove the splash shields.
Remove the fresh air duct, air cleaner assembly and air hose.
Remove the upper seal board (radiator bracket).
Remove the coolant reservoir and hose.
Disconnect the condenser and cooling fan motor connectors.
Remove the condenser and cooling fan motor assemblies.
Remove and plug the the oil cooler hose.
Remove the upper and lower radiator hoses.
Remove the radiator.
Disconnect the accelerator cable.
Loosen the locknut and adjuster bolt on the power steering belt tensioner and remove the belt. Remove the three power steering pump mounting bolts working through the pulley holes.
Remove the rear bracket bolt from the power steering pump and secure the pump aside with mechanics wire.
Remove the four A/C compressor mounting bolts, and secure the compressor aside with mechanics wire, leaving the refrigerant lines attached. Do not let the compressor hang by the refrigerant lines.
Remove the power steering hose bracket from the pump. Loosen the alternator belt tensioner locknut and adjuster bolt and remove the belt.
Disconnect the shift linkage from the transaxle.
Label and disconnect the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator. Label and disconnect any remaining engine harness connectors.
Label, disconnect and plug the fuel lines at the fuel rail.
Disconnect the heater hoses.
Raise and safely support the vehicle. Attach suitable engine lifting equipment to the lifting eyes on the engine.
Disconnect the oxygen sensor connector. Remove and discard the exhaust pipe-to-catalytic converter nuts.
Remove the exhaust support bolts. Remove and discard the exhaust pipe-to-exhaust manifold nuts and remove the exhaust pipe. Support the remaining exhaust system with mechanics wire.
Remove the upper lateral link link ball joint.
Remove the bolts and nuts from the lower arm ball joints, and pry the lower arms from the knuckles.
Separate the driveshafts and the joint shaft from the transaxle. Install transaxle plug tools T88C-7025-AH or equivalent, into the differential side gears.
NOTE: If the plugs are not installed, the differential side gears may become mispositioned. If the gears are mispositioned, the differential may have to be removed to reposition them.
Remove the number one engine mount stay (holder) and bracket.
Remove the crossmember. Remove the nuts from the engine mount number two.
Remove engine mount number four bracket.
Remove engine mount number three sub-bracket.
Lower the vehicle. Slowly lift the engine and transaxle assembly as a unit out of the vehicle. Keep the engine from swinging or bumping into components in the engine compartment.
Remove the starter. Remove the engine mount number two.
Remove the torque converter-to-flexplate nuts.
Remove the engine-to-transaxle bolts and the transaxle-to-engine mounting bolts.
Separate the engine from the transaxle.
Remove the flexplate.
Place the engine on a workstand.
To install:
Remove the engine from the workstand.
Remove the old sealant from the flexplate mounting bolts and bolt holes. If reusing the flexplate bolts, apply silicone sealant to the bolt threads. Install the flexplate and loosely install the bolts. Tighten the flexplate bolts in 2-3 steps to 75 ft. lbs. (103 Nm) in a crisscross pattern.
NOTE: New flexplate mounting bolts come with sealant already on them.
Install the transaxle-to-engine bolts and tighten the mounting bolts to 50-73 ft. lbs. (68-99 Nm).
Install the torque converter to the flexplate and tighten the nuts to 28-45 ft. lbs. (38-60 Nm). Rotate the flexplate, as necessary, to gain access to all of the nuts.
Install engine mount number two onto the transaxle and tighten to 28-38 ft. lbs. (38-51 Nm).
Install the starter and tighten the bolts to 28-38 ft. lbs. (38-51 Nm).
Suspend the engine and transaxle assembly. Slowly lower and position the assembly into the engine compartment. Align the engine mounts with the mount holes.
Install the crossmember, and tighten the three mounting bolts to 50-68 ft. lbs. (67-93 Nm).
Install the engine mounts.
Install a new clip on the joint shaft and install the shaft. Tighten the three mounting bolts to 32-45 ft. lbs. (43-61 Nm). Apply grease to the end of the joint shaft and the end of the driveshaft.
Remove the plugs and install the driveshaft. Install a new clip with the end gap facing upward. Push the driveshaft into the joint shaft. Pull the hub outward to confirm that the driveshaft is held securely.
Install the lower arm ball joint to the knuckle, and tighten the through-bolt to 58-86 ft. lbs. (79-116 Nm).
Install the upper lateral link ball joint using a new cotter pin, and tighten to 41-59 ft. lbs. (55-80 Nm).
Install the exhaust pipe to the catalytic converter and tighten the new nuts to 48-65 ft. lbs. (64-89 Nm).
Install the new exhaust pipe-to-exhaust manifold gasket and nuts and tighten to 28-38 ft. lbs. (38-51 Nm). Connect the oxygen sensor connector and lower the vehicle.
Connect the heater hoses.
Connect the fuel lines to the fuel rail.
Connect the engine wiring harness connectors including: the electrical connectors from the distributor, mass airflow sensor, intake air temperature sensor, engine coolant temperature sensor, cooling fan temperature sensor, coolant temperature gauge sensor, throttle position sensor, air bypass valve, idle switch, fuel injectors, EGR solenoids and alternator.
Connect the shift linkage to the transaxle.
Install the alternator belt and adjust the tension. Tighten the alternator upper mounting bolt to 18 ft. lbs. (25 Nm).
Raise and safely support the vehicle. Tighten the alternator through-bolt to 38 ft. lbs. (52 Nm).
Lower the vehicle.
Install the A/C compressor on the mounting bracket and tighten the bolts to 12-16 ft. lbs. (16-22 Nm).
Align the power steering pump and install the rear bracket bolt. Tighten to 34 ft. lbs. (46 Nm). Install the power steering hose bracket bolt and tighten to 34 ft. lbs. (46 Nm).
Install the three power steering pump bolts through the pulley and tighten to 34 ft. lbs. (46 Nm). Install the power steering belt and adjust the tension.
Install and adjust the accelerator cable.
Install the radiator.
Connect the radiator hoses.
Unplug and connect the oil cooler lines.
Install the condenser and cooling fan motor assemblies.
Connect the condenser and cooling fan motor connectors.
Install the coolant reservoir and hose.
Install the upper seal board.
Install the air cleaner, fresh air ducts and air hose.
Install the battery duct and carrier.
Install the battery tray, battery and battery clamp. Connect the battery cables.
Install the splash shields and front wheels.
Install the hood, aligning the marks that were made during removal.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Start the engine and bring to normal operating temperature. Check for leaks and proper engine operation.

1993-94 Miata 1.6L (B6-ZE) and 1.8L (BPD) Engines

Mark the position of the hood on its hinges and remove the hood.
Properly relieve the fuel system pressure.
Raise the trunk lid and disconnect the negative battery cable. Remove the fresh air duct and the air cleaner/air flow meter assembly.
Disconnect the accelerator cable from the throttle body.
Raise and safely support the vehicle and remove the undercover. Drain the engine and transmission oil and the coolant.
Disconnect the radiator hoses and the cooling fan electrical connector. Remove the radiator/cooling fans assembly.
Remove the accessory drive belts. Without disconnecting the hydraulic hoses, remove the power steering pump and secure it aside.
Without disconnecting the refrigerant, remove the air conditioner compressor and secure it aside.
Label and disconnect the wiring and all vacuum, fuel and coolant hoses.
Disconnect the exhaust pipe from the exhaust manifold.
Without disconnecting the hydraulic line, remove the clutch slave cylinder.
Remove the center console and the shifter assembly.
Disconnect the transmission electrical connectors and the speedometer cable.
Mark the position of the driveshaft on the differential flange and remove the bolts. Slide the driveshaft yoke from the transmission and remove the driveshaft.
The frame member between the transmission and differential must be removed. With the transmission properly supported, remove the bolts at both ends and remove the frame.
NOTE: Do not remove the upper frame-to-differential spacers from the frame. If they are removed, the entire frame must be replaced as a unit.
Install suitable lifting equipment onto the engine and make sure all hoses, wires and cables are disconnected.
Remove the engine mount nuts and lift the engine and transmission as an assembly from the vehicle.
Remove the starter.
If equipped with automatic transmission, remove the torque converter-to-flywheel bolts.
Remove the bolts to separate the transmission from the engine.
To install:
Assemble the engine to the transmission and torque the bolts to 66 ft. lbs. (89 Nm). If equipped with automatic transmission, install the torque converter-to-flywheel bolts and torque to 40 ft. lbs. (54 Nm).
Install the starter and torque the bolts to 38 ft. lbs. (52 Nm).
Carefully install the engine and transmission assembly into the vehicle. Start but do not tighten the mount nuts.
Install the transmission-to-differential frame and torque the bolts to 91 ft. lbs. (124 Nm). Torque the engine mount nuts to 58 ft. lbs. (78 Nm).
Connect the transmission wiring and speedometer cable and install the driveshaft. Torque the driveshaft bolts to 22 ft. lbs. (30 Nm).
Use a new gasket and attach the exhaust pipe to the manifold. Torque the nuts to 34 ft. lbs. (46 Nm).
Install the clutch slave cylinder and torque bolts to 19 ft. lbs. (25 Nm).
Connect and adjust the shift linkage as required.
Install the air conditioner compressor and power steering pump. Install and adjust the drive belts.
Install the radiator and fans and connect all cooling system hoses.
Connect all wiring and hoses.
Connect and adjust the accelerator cable as required.
Install the air cleaner and air flow meter assembly.
Check to make sure all wiring and hoses are properly connected. Fill and bleed the cooling system. Fill the engine and transmission with the proper type and quantity of oil.
Connect the negative battery cable, start the engine and bring to normal operating temperature. Check for leaks.
Check the ignition timing and idle speed. Check all fluid levels.

1995-97 Miata 1.8L (BPD) Engine

Properly relieve the fuel system pressure.
Raise the trunk lid and disconnect the negative battery cable. Remove the fresh air duct and the air cleaner/air flow meter assembly.
Remove the transmission.
Disconnect the accelerator cable from the throttle body.
Raise and safely support the vehicle and remove the undercover. Drain the engine oil and the coolant.
Disconnect the radiator hoses, including the coolant reservoir hose and the cooling fan electrical connector.
On automatic transmission vehicles only, remove the oil cooler hose.
Remove the radiator/cooling fan assembly.
Remove the accessory drive belts. Without disconnecting the hydraulic hoses, remove the power steering pump and secure it aside.
Without disconnecting the refrigerant, remove the air conditioner compressor and secure it aside.
Label and disconnect the following electrical connectors: Steering pressure sensor, throttle position sensor, idle air control valve, heated oxygen sensor, ignition coil, crankshaft position sensor, ground, fuel injector, alternator, oil pressure sensor and the starter.
Label and disconnect the following hoses: Brake vacuum, fuel, purge control vacuum, cruise control vacuum, water inlet and heater.
Disconnect the exhaust pipe from the exhaust manifold.
Install suitable lifting equipment onto the engine and make sure all hoses, wires and cables are disconnected.
Remove the engine mount nuts, and lift the engine from the vehicle.
To install:
Carefully and slowly install the engine assembly into the vehicle. Tilt the engine downward, and align the engine mounts with the crossmember mounting holes. Tighten the mount nuts to 42-57 ft. lbs. (57-78 Nm).
Use a new gasket and attach the exhaust pipe to the manifold. Torque the nuts to 34 ft. lbs. (46 Nm).
Install the following hoses: Brake vacuum, fuel, purge control vacuum, cruise control vacuum, water inlet and heater.
Install the following electrical connectors: Steering pressure sensor, throttle position sensor, idle air control valve, heated oxygen sensor, ignition coil, crankshaft position sensor, ground, fuel injector, alternator, oil pressure sensor and the starter.
Install the air conditioner compressor and power steering pump. Install and adjust the drive belts.
Install the radiator and fans, and connect all cooling system hoses.
Connect and adjust the accelerator cable as required.
Install the air cleaner and air flow meter assembly.
Install the transmission.
Check to make sure all wiring and hoses are properly connected. Fill and bleed the cooling system. Fill the engine and transmission with the proper type and quantity of oil.
Connect the negative battery cable, start the engine and bring to normal operating temperature. Check for leaks.
Check the ignition timing and idle speed. Check all fluid levels.

1993-95 RX7 1.3L (13B)

Mark the position of the hood on its hinges and remove the hood.
Properly relieve the fuel system pressure and disconnect the negative battery cable.
Remove the engine undercover and drain the engine oil and cooling system.
Remove the transmission.
Disconnect the Engine Control Module (ECM) as follows:
1. Open the passenger side door and remove the sill plate.
2. Remove the passenger side kick panel.
3. Disconnect the electrical connectors from the ECM.
Remove the fresh air duct, air cleaner intake hose and air cleaner.
Remove the battery, battery box and carrier.
Remove the strut bar, and temporarily tighten the locknut to the stud bolt.
Disconnect the accelerator cable, and remove the throttle body air intake hose.
Remove the upper and lower radiator hoses, and disconnect the heater hose.
Remove the (engine mounted) fuse box and position aside, leaving the wiring harness connected.
Remove the accessory drive belts.
Hold the power steering pump pulley using a suitable tool and remove the pulley nut. Remove the pulley. Remove the power steering pump and position aside, leaving the hoses connected.
Remove the A/C compressor and position aside, leaving the hoses connected.
Label and disconnect the engine wiring harness electrical connectors, and vacuum hoses. Disconnect and plug the fuel lines.
Position a drain pan under the engine oil cooler lines. Remove the clips and disconnect the hoses from the engine oil cooler.
Remove the insulators from the exhaust pipe and turbocharger. Do not let oil get on the insulators.
Disconnect the oxygen sensor connector and remove the front exhaust pipe. Remove the split air pipe.
If equipped with automatic transmission, disconnect the oil cooler lines at the radiator. Remove the bolt and nut from the line support brackets and remove the lines.
Attach suitable lifting equipment to the engine and remove the engine mount nuts. Carefully remove the engine from the vehicle and position on a workstand.
To install:
Carefully lower the engine into the vehicle, aligning the engine mounts with the crossmember mounting holes.
Install the engine mount nuts and tighten to 34-49 ft. lbs. (46-67 Nm). Remove the engine lifting equipment.
If equipped with automatic transmission, install and connect the transmission oil cooler lines. Tighten the support bracket nut and bolt to 95 inch lbs. (10.7 Nm).
Install the front exhaust pipe, using new gaskets. Tighten the exhaust pipe-to-turbocharger nuts to 38 ft. lbs. (51 Nm) and the exhaust pipe-to-main converter nuts to 65 ft. lbs. (89 Nm). Connect the split air pipe.
Install the front exhaust pipe insulator, turbocharger insulator and center insulator, in that order. Tighten the bolts, after all three insulators have been installed, to 95 inch lbs. (10.7 Nm).
Install the engine mount insulator and tighten the bolts to 95 inch lbs. (10.7 Nm).
Connect the engine oil cooler hoses to the engine oil cooler and install the clips. Make sure the clips are securely locked.
Connect the fuel lines, hoses and electrical connectors.
Install the A/C compressor and tighten the bolts to 18 ft. lbs. (25 Nm).
Install the power steering pump and tighten the bolts to 33 ft. lbs. (46 Nm). Connect the electrical connector to the pump.
Install the power steering pump pulley and loosely tighten the nut. Hold the pulley with a suitable tool and tighten the nut to 43 ft. lbs. (58 Nm).
Install the accessory drive belts, and adjust the belt tension.
Install the (engine mounted) fuse box and tighten the nut to 95 inch lbs. (10.7 Nm).
Install the radiator and heater hoses.
Install the throttle body air intake hose using a new gasket. Tighten the nuts to 95 inch lbs. (10.7 Nm). Connect the accelerator cable.
Remove the upper nuts and install the strut bar. Tighten the nuts to 26 ft. lbs. (36 Nm).
Install the air cleaner assembly and ducts. Tighten the bolts to 95 inch lbs. (10.7 Nm).
Install the carrier and battery box, and tighten the bolts to 95 inch lbs. (10.7 Nm). Install the battery.
Install the transmission.
Install the engine undercover.
Connect the ECM and install the kick panel and sill plate.
Fill the engine with the proper type and quantity of oil. Fill and bleed the cooling system.
Install the hood, aligning the marks that were made during removal.
Connect the battery cables, start the engine and bring to normal operating temperature. Check for leaks.
Check all fluid levels and road test.