ENGINE REMOVAL/INSTALLATION [MZR-CD 2.2]

id0110f2800400

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

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

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

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

5.  Remove the air cleaner component and air inlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

7.  Remove the dipstick.

8.  Disconnect the fuel main hose and fuel return hose.

9.  Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [MZR-CD 2.2].)

10.  Disconnect the heater hoses.

11.  Disconnect the upper radiator hose.

12.  Disconnect the charge air cooler inlet hose and charge air cooler outlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD 2.2].)

13.  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].)

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

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

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

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

18.  Remove the splash shields.

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

20.  Disconnect the front drive shaft from the transaxle. (See DRIVE SHAFT REMOVAL/INSTALLATION.)

21.  Remove the thermostat. (See THERMOSTAT REMOVAL/INSTALLATION [MZR-CD 2.2].)

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

23.  Remove the A/C compressor with the pipe still connected. Set the A/C compressor out of the way. Use wire or rope to secure it. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)

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

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

28.  Disconnect the wiring harness.

29.  Remove in the order shown in the table.

30.  Install in the reverse order of removal.

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

32.  Refill the transaxle oil. (See TRANSAXLE OIL REPLACEMENT [A26M-R].)

33.  Start the engine and:

•  Inspect the pulleys and the drive belt for runout and contact.
•  Inspect the engine oil, engine coolant transaxle oil, and fuel for leakage.
•  Inspect the idle speed. (See ENGINE TUNE-UP [MZR-CD 2.2].)

34.  Perform a road test.

35.  Reinspect the engine oil, engine coolant, transaxle oil.

am6zzw00004191

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


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

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

am6zzw00007982


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.

am6zzw00004192

Tightening torque
40—52 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}

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

am6zzw00007982

3.  Temporarily tighten the bolt and nuts shown in the figure.

am6zzw00004317

4.  Tighten the bolt and nuts in the order shown in the figure.

am6zzw00004318

Tightening torque
1.  112—131 N·m {12—13 kgf·m, 83—96 ft·lbf}
2.  99—115 N·m {10.1—11.7 kgf·m, 74—84 ft·lbf}

5.  Tighten the bolt shown in the figure.

am6zzw00004195

Tightening torque
86—116 N·m {8.8—11 kgf·m, 64—85 ft·lbf}