ENGINE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop]

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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 2.0 DISI i-stop].)

•  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.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

2.  Disconnect the negative battery cable. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

3.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

4.  Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

5.  Remove the air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

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

7.  Remove the aerodynamic under cover No.2 and splash shield as a single unit. (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.) (See SPLASH SHIELD REMOVAL/INSTALLATION.)

8.  Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT [G66M-R].)

9.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 2.0 DISI i-stop].)

10.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

11.  Disconnect the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

12.  Disconnect the evaporative hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

13.  Disconnect the brake vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [MZR 2.0, MZR 2.0 DISI i-stop, MZR 2.5].)

14.  Disconnect the radiator hose (upper and lower). (See RADIATOR REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

15.  Disconnect the water hose. (See THERMOSTAT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

16.  Disconnect the heater hose. (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

17.  Disconnect the power steering pipe component and then drain the power steering fluid. (See GENERAL PROCEDURES (STEERING).)

18.  Disconnect the shift cable and selector cable. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R (MZR 2.0 DISI i-stop)].)

19.  Remove the clutch release cylinder with the pipe still connected. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [G66M-R].)

20.  Remove the crossmember bracket. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop, SKYACTIV-G 2.0].)

21.  Remove the tunnel member (rear). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

22.  Set the TWC out of the way. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

23.  Disconnect the drive shafts from the engine side, set the drive shafts out of the way. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

24.  Remove the A/C drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop].)

25.  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 COMPRESSOR REMOVAL/INSTALLATION.)

26.  Remove the wiring harness installation bolt and nut shown in the figure.

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27.  Disconnect the ground cable from the cylinder head cover bracket (RH).

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

29.  Remove in the order indicated 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.)

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

•  Runout and contact of pulley and belt.

•  Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZR 2.0 DISI i-stop].)

•  Engine-driven accessories operation.

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1	Battery tray bracket
2	No.1 engine mount rubber, front crossmember component (See No.1 engine mount rubber, Front Crossmember Component Removal Note.) (See Engine Mount Installation Note.)
3	No.4 Engine mount rubber (See No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note.) (See Engine Mount Installation Note.)
4	No.3 Engine mount (See No.3 Engine Mount and No.4 Engine Mount Rubber Removal Note.) (See Engine Mount Installation Note.)
5	Engine, transaxle

No.1 engine mount rubber, Front Crossmember Component Removal Note

1.  Remove the No.1 engine mount rubber and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop, SKYACTIV-G 2.0].)

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

1.  Secure the engine and the transaxle using an engine jack and attachment as shown in the figure.

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Engine Mount Installation Note

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

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

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3.  Temporarily tighten the No.3 engine mount installation bolts and nuts.

Note

•  Do not tighten the bolt during this step.

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4.  Temporarily tighten the No.4 engine mount rubber installation bolt.

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5.  Install the No.1 engine mount rubber and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 2.0 DISI i-stop, SKYACTIV-G 2.0].)

6.  Temporarily tighten the No.1 engine mount rubber installation bolts in the order as shown in the figure.

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7.  Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.

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8.  Tighten the No.4 engine mount rubber installation bolt as shown in the figure.

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9.  Tighten the No.1 engine mount rubber installation bolts as shown in the figure.

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Caution

•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.