ENGINE REMOVAL/INSTALLATION [MZR 2.0 DISI]

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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].)

Caution

•  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 plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [MZR 2.0 DISI].)

2.  Remove the air hose and air cleaner component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

3.  Remove the PCM and PCM bracket component. (See PCM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

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

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

6.  Remove the aerodynamic under cover No.1 and No.2. (See AERODYNAMIC UNDER COVER NO.1 REMOVAL/INSTALLATION.) (See AERODYNAMIC UNDER COVER NO.2 REMOVAL/INSTALLATION.)

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

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

9.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR 2.0 DISI].)

10.  Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR 2.0 DISI].)

11.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [MZR 2.0 DISI].)

12.  Drain the ATF (ATX) or transaxle oil (MTX). (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FS5A-EL] (ATX).) (See TRANSAXLE OIL REPLACEMENT [G66M-R] (MTX).)

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

14.  Disconnect the lower radiator hose from the engine side. (See THERMOSTAT REMOVAL/INSTALLATION [MZR 2.0 DISI].)

15.  Disconnect the brake vacuum hose from the intake manifold side. (See VACUUM HOSE REMOVAL/INSTALLATION [MZR 1.8, MZR 2.0, MZR 2.0 DISI, MZR 2.5].)

16.  Disconnect the evaporative hose from the purge solenoid valve. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [MZR 2.0 DISI].)

17.  Disconnect the upper radiator hose and water hose from the engine side. (See COOLING FAN MOTOR REMOVAL/INSTALLATION [MZR 2.0 DISI].)

18.  Disconnect the heater hoses. (See A/C UNIT REMOVAL/INSTALLATION.)

19.  Disconnect the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [MZR 2.0 DISI].)

20.  Disconnect the ATF oil hose, selector cable, and wiring harness. (ATX) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FS5A-EL].)

21.  Disconnect the shift cable. (MTX) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R] (MTX).)

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

23.  Set the cooler hose (LO) out of the way. (See REFRIGERANT LINE REMOVAL/INSTALLATION.)

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

25.  Remove the wiring harness installation bolt and nuts shown in the figure.

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

27.  Remove in the order indicated in the table.

28.  Install in the reverse order of removal.

29.  Start the engine. And inspect and adjust the following:

•  Leakage of engine oil, engine coolant, ATF (ATX), transaxle oil (MTX), and fuel.

•  Runout and contact of pulley and belt.

•  Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [MZR 2.0 DISI].)

•  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	No.1 engine mount (See No.1 Engine Mount Removal Note.) (See Engine Mount Installation Note.)
2	No.4 Engine mount bracket (See No.3 Engine Mount Bracket, No.4 Engine Bracket Removal Note.) (See Engine Mount Installation Note.)
3	No.3 Engine mount bracket (See No.3 Engine Mount Bracket, No.4 Engine Bracket Removal Note.) (See Engine Mount Installation Note.)
4	Engine, transaxle

No.1 Engine Mount Removal Note

Note

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

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

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

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Engine Mount Installation Note

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

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

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3.  Temporarily tighten the No.3 engine mount bracket installation bolt and nuts.

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4.  Align the No.4 engine mount bracket installation hole to the No.4 engine mount rubber on the body and temporarily tighten the bolt shown in the figure.

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5.  Temporarily tighten the No.4 engine mount bracket installation bolt and nuts.

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

7.   Tighten the No.1 engine mount bracket installation bolts.

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8.  Temporarily tighten the No.1 engine mount rubber installation bolts.

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9.  Tighten the No.3 engine mount bracket installation bolt and nuts in the order shown in the figure.

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10.  Tighten the No.4 engine mount bracket installation bolts and nuts in the order shown in the figure.

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11.  Tighten the bolt shown in the figure.

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

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