ENGINE REMOVAL/INSTALLATION [MZR-CD (RF Turbo)]

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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 injures 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 (RF Turbo)].)

1.  Remove the engine cover. (See TIMING BELT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

2.  Remove the battery and tray. (See BATTERY REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

3.  Remove the air cleaner and air hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

4.  Disconnect the fuel hose. (See BEFORE SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

5.  Remove the both front tires.

6.  Remove the aerodynamic under cover No.2. (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.

9.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

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

11.  Remove the oxidation catalytic converter. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

12.  Disconnect the front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

13.  Drain the engine coolant and transaxle oil.

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

15.  Disconnect the radiator hose. (See RADIATOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

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

17.  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.)

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

19.  Remove the starter. (See STARTER REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

20.  Disconnect the vacuum hose and the heater hose.

21.  Remove PTC heater. (With PTC heater) (See PTC (POSITIVE TEMPERATURE COEFFICIENT) HEATER REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) (See PTC (POSITIVE TEMPERATURE COEFFICIENT) HEATER REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

22.  Disconnect the wiring harness.

23.  Remove in the order indicated in the table.

24.  Install in the reverse order of removal.

25.  Fill the engine coolant and transaxle oil.

26.  Bleed the air from the fuel line. (See AFTER SERVICE PRECAUTION [MZR-CD (RF Turbo)].)

27.  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 (RF Turbo)].)

28.  Perform a road test.

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

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

1.  Install the through bolt A on the front crossmember side until approximately three pitches are showing.

2.  Temporarily tighten bolts B and C.

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Note
•  If the No.3 engine mount bracket and the engine are removed, retighten the No.3 engine mount stud bolts.

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

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Tightening torque
28—40 N·m {2.9—4.0 kgf·m, 21—29 ft·lbf}

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

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5.  Temporarily the No.3 engine mount bracket nuts in the figure.

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

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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}

7.  Align the No.4 engine mount bracket installation hole to the No.4 engine mount rubber on the body and temporarily tighten bolt D.

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8.  Temporarily tighten bolt E, and then the nuts in the order of F, G.

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9.  Tighten bolt E, and then the nuts in the order of F, G.

Tightening torque
67—93 N·m {6.9—9.4 kgf·m, 50—68 ft·lbf}

10.  Tighten the bolt D.

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

11.  Tighten the bolt H.

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Tightening torque
60—80 N·m {6.2—8.1 kgf·m, 45—59 ft·lbf}

12.  Tighten the bolts in the order of B and C.

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Tightening torque
94—116 N·m {9.6—11 kgf·m, 70—85 ft·lbf}

13.  Tighten the bolt A.

Tightening torque
94—116 N·m {9.6—11 kgf·m, 70—85 ft·lbf}