ENGINE REMOVAL/INSTALLATION [MZR-CD 2.2]

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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.
•  If the timing chain is replaced, always perform each adjustment procedure using the following steps.

STEP

ACTION

PAGE/CONDITION
1
Replace the timing chain.
—
2
Start the engine.
—
3
Perform the injection amount correction procedure.
Engine coolant temperature: 65—95 °C {149—203 °F}
Intake air temperature: 15—65 °C {59—149 °F}
Fuel temperature: 30—60 °C {86—140 °F}
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [MZR-CD 2.2].)
4
Perform the timing chain correction procedure.
Engine coolant temperature: 65—95 °C {149—203 °F}
Intake air temperature: 15—65 °C {59—149 °F}
Fuel temperature: 30—60 °C {86—140 °F}
(See TIMING CHAIN CORRECTION [MZR-CD 2.2].)
5
Perform after repair procedure.
(See AFTER REPAIR PROCEDURE [MZR-CD 2.2].)
6
Switch the ignition to off.
—

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

2.  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.)

3.  Set the front mudguards out of the way. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

4.  Remove the front splash shields. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

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

6.  Drain the transaxle oil. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

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

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

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

10.  Remove the air cleaner component, air hose and fresh-air duct (No1, No2). (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

11.  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].)

12.  Remove the air inlet pipe and turbocharger air outlet pipe No.2. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

13.  Disconnect the heater hoses.

14.  Disconnect the vacuum hose.

15.  Disconnect the fuel hoses.

16.  Remove the boost sensor. (See COMMON RAIL REMOVAL/INSTALLATION [MZR-CD 2.2].)

17.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [MZR-CD 2.2].)

18.  Disconnect the upper radiator hose and water hose.

19.  Set the shift cable, selector cable and clutch release cylinder parts related to the transaxle out of the way. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R (MZR-CD 2.2)].)

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

21.  Remove the nut shown in the figure.

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22.  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.)

23.  Remove the cooling fan component. (See COOLING FAN COMPONENT REMOVAL/INSTALLATION [MZR-CD 2.2].)

24.  Remove the lower radiator hose.

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

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

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

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

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

30.  Remove in the order shown in the table.

31.  Install in the reverse order of removal.

32.  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.
•  Idle speed. (See ENGINE TUNE-UP [MZR-CD 2.2].)
•  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, No.4 Engine Mount Rubber Removal Note.)
(See Engine Mount Installation Note.)
4
No.3 engine mount
(See No.3 Engine Mount, 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.  Loosen the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure.

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2.  Remove the No.1 engine mount rubber installation bolt (No.1 engine mount bracket side) shown in the figure.

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3.  Remove the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)


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

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

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Engine Mount Installation Note

Note
•  When loosening the No.3 engine mount nuts, always tighten the No.3 engine mount bracket stud bolts. When the No.3 engine mount nuts are loosened, the No.3 engine mount bracket stud bolts could become loose.

1.  Tighten the No.3 engine mount 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 transaxle using an engine jack.

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3.  Temporarily tighten the No.3 engine mount 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.

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5.  Install the front crossmember component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

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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.  75—104 N·m {7.7—10 kgf·m, 56—76 ft·lbf}
2.  71—93 N·m {7.3—9.4 kgf·m, 53—68 ft·lbf}

8.  Tighten the No.4 engine mount rubber installation bolt.

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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.

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Tightening torque
73—90 N·m {7.5—9.1 kgf·m, 54—66 ft·lbf}