ENGINE REMOVAL/INSTALLATION [MZR-CD 2.2]SM2444607
ENGINE REMOVAL/INSTALLATION [MZR-CD 2.2]

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Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION [MZR-CD 2.2].)
Caution
• Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.
Note
• Perform the engine and transaxle component removal/installation from below the vehicle.
• If the timing chain is replaced, always perform each adjustment procedure using the following steps.

STEP

ACTION

PAGE/CONDITION
1
Replace the timing chain.
—
2
Start the engine.
—
3
Perform the injection amount correction procedure.
Engine coolant temperature: 65—95 °C {149—203 °F}
Intake air temperature: 15—65 °C {59—149 °F}
Fuel temperature: 30—60 °C {86—140 °F}
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [MZR-CD 2.2].)
4
Perform the timing chain correction procedure.
Engine coolant temperature: 65—95 °C {149—203 °F}
Intake air temperature: 15—65 °C {59—149 °F}
Fuel temperature: 30—60 °C {86—140 °F}
(See TIMING CHAIN CORRECTION [MZR-CD 2.2].)
5
Perform after repair procedure.
(See AFTER REPAIR PROCEDURE [MZR-CD 2.2].)
6
Switch the ignition to off.
—

1.Disconnect the negative battery cable.

2.Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZR-CD 2.2].)

3.Disconnect the positive battery cable shown in the figure.
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4.Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

5.Remove the front wheels and tires. (See GENERAL PROCEDURES (SUSPENSION).)

6.Remove the under cover.

7.Set the front mudguards out of the way.

8.Remove the front splash shields.

9.Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR-CD 2.2].)

10.Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT [A26MX-R].)

11.Remove the air cleaner component, air hose, fresh-air duct and air cleaner bracket. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

12.Disconnect the upper radiator hose.

13.Remove the charge air cooler air inlet hose and charge air cooler air outlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

14.Remove the wiring harness installation bolt shown in the figure.
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15.Disconnect the connectors and the wiring harnesses related to the engine removal/installation.

16.Set the shift cable, selector cable and clutch release cylinder parts related to the transaxle out of the way. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26MX-R (MZR-CD 2.2)].)

17.Disconnect the brake vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION.)

18.Disconnect the heater hoses. (See A/C UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) (See A/C UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

19.Disconnect the fuel hoses. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

20.Remove the nut and set the cooler hose (LO) out of the way in the direction shown in the figure.
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21.Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR-CD 2.2].)

22.Disconnect the lower radiator hose from the radiator. (See RADIATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

23.Remove the thermostat and the lower radiator hose as a single unit. (See THERMOSTAT REMOVAL/INSTALLATION [MZR-CD 2.2].)

24.Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (See A/C UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) (See A/C UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

25.Remove the seal plate. (See OIL PAN REMOVAL/INSTALLATION [MZR-CD 2.2].)

26.Remove the oxidation catalytic converter (built-in diesel particulate filter). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

27.Disconnect the drive shafts from the engine side, set the drive shafts out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L5, MZR-CD 2.2].)

28.Disconnect the propeller shaft from the engine side, set the propeller shaft out of the way. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

29.Remove in the order shown in the table.

30.Install in the reverse order of removal.

31.Start the engine. And inspect and adjust the following:

• Front wheel alignment (See FRONT WHEEL ALIGNMENT.)
• Power steering fluid air bleeding (See AIR BLEEDING [MZR-CD 2.2].)
• Leakage of engine oil, engine coolant, transaxle oil, and fuel.
• Runout and contact of pulley and belt.
• Verify the idle speed. (See ENGINE TUNE-UP [MZR-CD 2.2].)
• Engine-driven accessories operation.

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1
No.1 engine mount
(See No.1 Engine Mount Removal Note.)
(See Engine Mount Installation Note.)
2
No.3 engine mount
(See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.)
(See Engine Mount Installation Note.)
3
No.4 engine mount rubber
(See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.)
(See Engine Mount Installation Note.)
4
Engine, transaxle


No.1 Engine Mount Removal Note

1.Loosen the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure.
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2.Remove the No.1 engine mount rubber installation bolt (No.1 engine mount bracket side) shown in the figure.
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3.Remove the No.1 engine mount rubber and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)
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No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note

1.Secure the engine and transaxle using an engine jack.
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Engine Mount Installation Note

1.Tighten the No.3 engine mount stud bolts.

Note
• When loosening the No.3 engine mount nuts, always tighten the No.3 engine mount bracket stud bolts. When the No.3 engine mount nuts are loosened, the No.3 engine mount bracket stud bolts could become loose.
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Tightening torque
40—52 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}

2.Secure the engine and transaxle using an engine jack.
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3.Temporarily tighten the No.3 engine mount bolts and nuts.

4.Tighten the No.3 engine mount bolts and nuts in the order shown in the figure.
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Tightening torque
75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}

5.Temporarily tighten the No.4 engine mount bracket in the order shown in the figure.
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6.Tighten the No.4 engine mount bracket in the order shown in the figure.
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Tightening torque
75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}

7.Install the front crossmember component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)

8.Temporarily tighten the No.1 engine mount bracket.

9.Tighten the No.1 engine mount bracket shown in the figure.
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Tightening torque
108—134 N·m {12—13 kgf·m, 80—98 ft·lbf}

10.Temporarily tighten the No.1 engine mount rubber.

11.Tighten the No.1 engine mount rubber installation bolt (No.1 engine mount bracket side) shown in the figure.
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Tightening torque
108—134 N·m {12—13 kgf·m, 80—98 ft·lbf}

12.Tighten the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure.
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Tightening torque
105—132 N·m {11—13 kgf·m, 78—97 ft·lbf}