ENGINE REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo]

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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 [MZ-CD 1.4 DI Turbo].)
Note
•  Perform the engine and transaxle component removal/installation from below the vehicle.

1.  Complete the "Fuel Line Safety Procedure". (See BEFORE SERVICE PRECAUTION [MZ-CD 1.4 DI Turbo].)

2.  Remove the battery. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

3.  Remove the battery tray. (See PCM REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

4.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.4 DI Turbo].)

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

6.  Remove the drive belt. (See DRIVE BELT REPLACEMENT [MZ-CD 1.4 DI Turbo].)

7.  Disconnect the radiator hose.

8.  Remove the air cleaner cover, fresh-air duct and air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

9.  Remove the fuel filter protector. (See FUEL FILTER REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

10.  Disconnect the fuel hose.

11.  Set the cooler pipe and cooler hose (LO) out of the way. (With A/C) (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

Note
•  Secure the A/C compressor using wire or rope so that it is out of the way. (With A/C)

12.  Remove the A/C compressor with the pipes still connected. (With A/C) (See A/C COMPRESSOR REMOVAL/INSTALLATION.)

13.  Disconnect the front drive shafts. (See DRIVE SHAFT REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)].)

14.  Remove the front crossmember. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

15.  Disconnect the shift cable. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [B65M-R (MZ-CD 1.4 DI Turbo)].)

16.  Disconnect the vacuum hose and heater hose.

17.  Disconnect the wiring harness from the engine side.

18.  Remove the oil level gauge pipe.

19.  Remove the catalytic converter and front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.4 DI Turbo].)

20.  Remove the clutch pipe connector. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [B65M-R (MZ-CD 1.4 DI Turbo)].)

21.  Remove in the order indicated in the table.

22.  Install in the reverse order of removal.

23.  Bleed the air from the clutch fluid. (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT [B65M-R].)

24.  Start the engine. and inspect and adjust the following:

•  Leakage of engine oil, engine coolant, transaxle oil, and fuel
•  Pulley and belt for runout and contact
•  Engine-driven accessories operation
Note
•  If the engine is overhauled and assembled to the vehicle, perform a road test to verify that there is no abnormal vibration and noise.

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1
No.1 Engine mount rubber
(See No.1 Engine Mount Removal Note.)
(See No.1 Engine Mount Installation Note.)
2
Battery tray bracket
3
No.4 Engine mount rubber
(See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.)
(See No.3 Engine Mount, No.4 Engine Mount Rubber Installation Note.)
4
No.3 Engine mount
(See No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note.)
(See No.3 Engine Mount, No.4 Engine Mount Rubber Installation Note.)
5
Engine, transaxle


No.1 Engine Mount Removal Note

1.  Remove the installation bolts (A) from below the vehicle.

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2.  Loosen the installation bolt (B).

3.  Remove the No.1 engine mount rubber and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)


No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note

Caution
•  Do not loosen the bolt shown in the figure because it cannot be installed properly once it is if loosened once.
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1.  Secure the engine and the transaxle using an engine jack.

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No.3 Engine Mount, No.4 Engine Mount Rubber Installation Note

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

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Tightening torque
12—15 N·m {123—152 kgf·cm, 107—132 in·lbf}

2.  Secure the engine and the transaxle using an engine jack.

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3.  Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts.

4.  Tighten the installation nuts and bolts by order of A, B.

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Tightening torque
62—76 N·m {6.4—7.7 kgf·m, 46—56 ft·lbf}

5.  Install the No.4 engine mount rubber, and then temporarily tighten the installation bolts and nuts.

6.  Tighten the installation nuts and bolts by order of A, B.

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Tightening torque
74—105 N·m {7.6—10 kgf·m, 55—77 ft·lbf}


No.1 Engine Mount Installation Note

1.  Install the No.1 Engine mount rubber, and then temporarily tighten the installation bolts.

2.  Tighten the installation bolts (A).

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Tightening torque
54—61 N·m {5.6—6.2 kgf·m, 40—44 ft·lbf}

3.  Tighten the installation bolt (B).

Tightening torque
43—55 N·m {4.4—5.6 kgf·m, 32—40 ft·lbf}

4.  Remove the engine jack.