ENGINE REMOVAL/INSTALLATION [MZI-3.7]

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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 [MZI-3.7].)

1.  Perform “Fuel Line Safety Procedures”. Leave the fuel pump relay removed. (See BEFORE SERVICE PRECAUTION [MZI-3.7].)

2.  Disconnect both battery cables.

3.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [MZI-3.7].)

4.  Drain the power steering fluid. (See POWER STEERING FLUID INSPECTION.)

5.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZI-3.7].)

6.  Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [MZI-3.7].)

7.  Remove the ventilation hose. (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7].)

8.  Disconnect the vacuum hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

9.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

10.  Remove the resonance chamber. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

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

12.  Remove the splash shield (RH).

13.  Remove the generator and A/C drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZI-3.7].)

14.  Disconnect the front drive shaft (RH) from the joint shaft side. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

15.  Disconnect the front drive shaft (LH) from the transaxle side. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

16.  Remove the front pipe and middle pipe as a single unit. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZI-3.7].)

17.  Position the propeller shaft out of the way. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

18.  Disconnect the selector cable from the transaxle side. (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [AW6AX-EL].)

19.  Disconnect the heater hose. (See HEATER PIPE AND HOSE COMPONENT REMOVAL/INSTALLATION.)

20.  Remove the engine hanger installation bolt, and power steering oil pump hose out of the way (R.H.D.). (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [R.H.D.].)

21.  Disconnect the power steering return hose. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [L.H.D.].) (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [R.H.D.].)

22.  Disconnect the radiator hose. (See RADIATOR REMOVAL/INSTALLATION [MZI-3.7].)

23.  Disconnect the water hose. (See OIL COOLER REMOVAL/INSTALLATION [MZI-3.7].)

24.  Disconnect the ATF oil cooler hose.

25.  Disconnect the plastic fuel hose. (See BEFORE SERVICE PRECAUTION [MZI-3.7].) (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [MZI-3.7].)

26.  Disconnect the wiring harness.

Note
•  Do not disconnect the engine side of this wiring harness.

27.  Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)

28.  Remove the engine and transaxle component using an engine jack in the order indicated in the figure.

29.  Install in the reverse order of removal.

30.  Start the engine and:

(1)  Inspect the runout and contact on the pulley and belt.
(2)  Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.
(3)  Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZI-3.7].)
(4)  Engine accessories operation

31.  Perform a road test.

Note
•  If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no malfunction.
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1
No.1 engine mount
(See No.1 Engine Mount Removal Note.)
2
No.3 engine mount rubber
(See No.3 Engine Mount Rubber and No.4 Engine Mount Bracket Removal Note.)
(See Engine Mount Installation Note.)
3
No.3 engine mount stay (No.3 engine mount side)
4
No.4 engine mount bracket
(See No.3 Engine Mount Rubber and No.4 Engine Mount Bracket Removal Note.)
(See Engine Mount Installation Note.)
5
Engine and transaxle
(See Engine and Transaxle Removal Note.)


No.1 Engine Mount Removal Note

1.  Remove the front under cover A and front under cover B. (See FRONT UNDER COVER REMOVAL/INSTALLATION.)

2.  Remove the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)

3.  Remove the intermediate shaft installation bolt, and disconnect the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

4.  Remove the No.1 engine mounting bracket bolts.

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5.  Remove the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [L.H.D.].) (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.].)

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No.3 Engine Mount Rubber and No.4 Engine Mount Bracket Removal Note

1.  Secure the engine and transaxle using an engine jack and attachment.

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Caution
•  Remove the engine and transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

2.  Secure the engine, transaxle, and crossmember component using a hoist.


Engine and Transaxle Removal Note

Note
•  When lowering the engine, slightly move it to the left side of the vehicle to set the A/C compressor out of the way.
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Engine Mount Installation Note

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

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Tightening torque
15.7—23.5 N·m {1.61—2.39 kgf·m, 11.6—17.3 ft·lbf}

2.  Secure the engine and the transaxle using an engine jack and attachment as shown.

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3.  Temporarily tighten the No.3 engine mount bolt and nuts in the order shown in the figure.

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4.  Temporarily tighten the No. 4 engine mount bracket in two passes.

(1)  Temporarily tighten the No.4 engine mount bracket in the order shown in the figure until the flange surface does not adhere.
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(2)  Temporarily tighten the No.4 engine mount bracket in the order shown in the figure until the flange surface firmly adheres.
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5.  Install the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [L.H.D.].) (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.].)

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6.  Tighten the No.1 engine mount bracket bolt A and B in order of A→B.

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Tightening torque
Bolt A, B: 93.1—116.6 N·m {9.5—11.8 kgf·m, 68.7—85.9 ft·lbf}

Note
•  When replacing bolt C on the crossmember side, always replace it with a bolt of the same size as the removed one.

7.  Tighten the No.1 engine mount bolt C at the specified torque.

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Tightening torque
M12 bolt: 93.1—116.6 N·m {9.5—11.8 kgf·m, 68.7—85.9 ft·lbf}
M14 bolt: 104.2—132.6 N·m {10.6—13.5 kgf·m, 76.9—97.8 ft·lbf}

8.  Install the intermediate shaft installation bolt, and disconnect the steering shaft. (See STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)

9.  Install the transverse member. (See TRANSVERSE MEMBER REMOVAL/INSTALLATION.)

10.  Install the front under cover A and front under cover B. (See FRONT UNDER COVER REMOVAL/INSTALLATION.)

11.  Tighten the No.3 engine mount in the order shown in the figure.

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Tightening Torque

Installation Position

Tightening Torque
1, 2, 7
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—77.3 ft·lbf}
3, 4, 5, 6
43.1—74 N·m {4.40—7.54 kgf·m, 31.8—54.5 ft·lbf}

12.  Tighten the No.3 engine mount stay (No.3 engine mount side).

Tightening torque
43.1—60.7 N·m {4.40—6.18 kgf·m, 31.8—44.7 ft·lbf}

13.  Tighten the No.4 engine mount in the order shown in the figure.

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Tightening Torque

Installation Position

Tightening Torque
1, 2, 3
66.6—93.1 N·m {6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
4
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—77.3 ft·lbf}