ENGINE REMOVAL/INSTALLATION [MZ-CD 1.6]

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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 1.6].)
Note
•  Perform the engine and transaxle component removal/installation from below the vehicle.

1.  Remove the battery cover. (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

2.  Disconnect the negative battery cable.

3.  Remove the engine cover (See ENGINE COVER REMOVAL/INSTALLATION [MZ-CD 1.6].)

4.  Remove the battery box, battery clamp, battery and battery tray (See BATTERY REMOVAL/INSTALLATION [MZ-CD 1.6].)

5.  Remove the front wheels and tires. (See GENERAL PROCEDURES (FRONT AND REAR AXLES).)

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

7.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZ-CD 1.6].)

8.  Drain the transaxle oil. (See MANUAL TRANSAXLE OIL REPLACEMENT [B76M-R].)

9.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6].)

10.  Disconnect the upper and lower radiator hose.

11.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZ-CD 1.6].)

12.  Remove the air cleaner. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

13.  Remove the charge air cooler pipe and hose, air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

14.  Disconnect the fuel hose (fuel filter side).

15.  Remove fuel filter protector. (See FUEL FILTER REMOVAL/INSTALLATION [MZ-CD 1.6].)

16.  Remove the catalytic converter and front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZ-CD 1.6].)

17.  Disconnect the shift cable. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [B76M-R].)

18.  Remove the A/C compressor with the pipes still connected

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

19.  Disconnect and/or remove the following parts related to the suspension and axle.

(1)  Disconnect the ABS wheel-speed sensor connectors from the steering knuckles. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)
(2)  Disconnect the brake hose from the shock absorber. (See BRAKE HOSE (FRONT) REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)
(3)  Disconnect the tie-rod end ball joints from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)
(4)  Disconnect the front lower arms from the steering knuckles. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)
(5)  Disconnect the stabilizer control links from the shock absorbers (upper side). (See FRONT STABILIZER REMOVAL/INSTALLATION [EXCEPT MZR 2.3 DISI Turbo].)
(6)  Disconnect the drive shaft (LH) from the transaxle. (See DRIVE SHAFT REMOVAL/INSTALLATION.)
(7)  Disconnect the drive shaft (RH) from the joint shaft. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

20.  Disconnect the vacuum hose and heater hose.

21.  Disconnect the wiring harness from the engine side.

22.  Remove in the order indicated in the table.

23.  Install in the reverse order of removal.

24.  Bleed the air from the clutch fluid. (See CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)

25.  Inspect the following and adjust them if necessary.

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

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1
Main fuse block connector
2
Battery tray bracket
3
No.1 Engine mount rubber, front crossmember component
(See No.1 Engine Mount Rubber, Front Crossmember Component Removal Note.)
(See Engine Mount Installation Note.)
4
No.4 Engine mount rubber
(See Engine Mount Installation Note.)
5
No.3 Engine mount rubber
(See No.3 Engine Mount Rubber Removal Note.)
(See Engine Mount Installation Note.)
6
Engine, transaxle


No.1 Engine Mount Rubber, Front Crossmember Component Removal Note

1.  Remove the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)


No.3 Engine Mount Rubber Removal Note

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

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Engine Mount Installation Note

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

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Tightening torque
7—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

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

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

Note
•  Do not tighten the bolts and nuts during this step.
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4.  Temporarily tighten the No.4 engine mount rubber installation bolt shown in the figure.

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5.  Install the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR 1.5, MZR 1.6, MZR 2.0, MZR 2.3 DISI Turbo, MZR 2.5, MZ-CD 1.6].)

6.  Temporarily tighten bolts in the order shown in the figure.

Caution
•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.
•  Tighten the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.
Bolt length (measured from below the head)
Front crossmember side: 62 mm {2.4 in}
No.1 engine mount bracket side: 65 mm {2.6 in}
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Note
•  Do not tighten the bolts during this step.

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

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Tightening torque
1 (nuts): 75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}
2 (bolts): 71—93 N·m {7.3—9.4 kgf·m, 53—68 ft·lbf}

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

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Tightening torque
94—131 N·m {9.6—13 kgf·m, 70—96 ft·lbf}

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

Caution
•  Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.
Tightening torque
73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}
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