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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].)

• 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.

1.Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

3.Remove the under cover.

4.Set the front mudguards out of the way.

5.Remove the front splash shields.

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

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

8.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].)

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

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

11.Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

13.Disconnect the upper radiator hose and water hose.

14.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].)

15.Remove the wiring harness installation bolt shown in the figure.

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16.Disconnect the connectors and the wiring harnesses related to the engine removal/installation.

17.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)].)

18.Disconnect the vacuum hose.

19.Disconnect the heater hoses.

20.Disconnect the fuel hoses.

21.Disconnect the exhaust gas pressure hoses. (See EXHAUST GAS PRESSURE SENSOR/EXHAUST GAS PRESSURE CORRECTION TEMPERATURE SENSOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

22.Remove the nut and set the cooler hose out of the way in the direction shown in the figure.

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23.Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR-CD 2.2].)

24.Disconnect the lower radiator hose from the radiator.

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

26.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 [MANUAL AIR CONDITIONER].)(See A/C UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

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

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

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

30.Remove the No.4 engine mount bracket.

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31.Remove the EGR cooler and EGR cooler bypass valve component. (See EGR COOLER REMOVAL/INSTALLATION [MZR-CD 2.2].)

32.Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZR-CD 2.2].)

33.Remove the generator duct. (See GENERATOR REMOVAL/INSTALLATION [MZR-CD 2.2].)

34.Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [4WD].)

35.Remove the transfer. (See TRANSFER REMOVAL/INSTALLATION [A26MX-R (MZR-CD 2.2)].)

36.Remove the manual transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26MX-R (MZR-CD 2.2)].)

37.Remove in the order shown in the table.

38.Install in the reverse order of removal.

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

• Front wheel alignment (See FRONT WHEEL ALIGNMENT.)

• Power steering fluid air bleeding (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)

• Leakage of engine oil, engine coolant, transaxle oil.

• 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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Clutch Cover and Disc Removal Note

Caution

• When replacing components, always replace as a complete set.

• Due to the automatic adjustment function of clutch cover, if the old cover assembly is reused, it must be reinstalled together with its original clutch disc.

1.Install the SSTs.

2.Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.

3.Remove the clutch cover and disc.

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Pilot Bearing Removal Note

Note

• The pilot bearing does not need to be removed unless you are replacing it.

1.Use the SST to remove the pilot bearing.

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Flywheel Removal Note

1.Hold the flywheel using the SST.

2.Remove the bolts evenly and gradually in a crisscross pattern.

3.Remove the flywheel.

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Flywheel Installation Note

Caution

• Clean the crankshaft threads before tightening the bolts. The threads may be damaged if the bolts are tightened with any old sealant remaining.

1.Clean the crankshaft thread holes.

2.Install the flywheel to the crankshaft.

3.Hand‐tighten the new flywheel lock bolts.

4.Install the SST to the flywheel.

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5.Gradually tighten the flywheel lock bolts in a crisscross pattern.

Pilot Bearing Installation Note

1.Use the SSTs to install the pilot bearing.

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2.As shown in the figure, press-fit the pilot bearing to the position which is 4.0—5.0 mm {0.16—0.19 in} from the crankshaft end.

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Clutch Disc Installation Note

1.Hold the clutch disc position using the SST.

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Clutch Cover Installation Note

1.Install the SSTs.

2.Tighten the bolts evenly and gradually in a crisscross pattern.

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