Removal and Replacement

ENGINE REMOVAL/INSTALLATION [MZI-3.7]

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". Before Service Precaution

1. Perform "Fuel Line Safety Procedures". Leave the fuel pump relay removed. Before Service Precaution

2. Disconnect both battery cables.

3. Remove the battery and battery tray. Removal and Replacement

4. Drain the power steering fluid. Initial Inspection and Diagnostic Overview

5. Drain the engine coolant. Service and Repair

6. Remove the engine cover. Service and Repair

7. Remove the ventilation hose. Service and Repair

8. Disconnect the vacuum hose. Service and Repair

9. Remove the air cleaner. Service and Repair

10. Remove the resonance chamber. Service and Repair

11. Remove the both front wheels and tires. Service and Repair

12. Remove the splash shield (RH).

13. Remove the generator and A/C drive belt. Service and Repair

14. Disconnect the front drive shaft (RH) from the joint shaft side. Front Drive Shaft Removal/Installation

15. Disconnect the front drive shaft (LH) from the transaxle side. Front Drive Shaft Removal/Installation

16. Remove the front pipe and middle pipe as a single unit. Service and Repair

17. Position the propeller shaft out of the way. (AWD) Service and Repair

18. Disconnect the selector cable from the transaxle side. Automatic Transaxle Removal/Installation

19. Disconnect the heater hose. Service and Repair

20. Disconnect the power steering return hose. Removal and Replacement

21. Disconnect the radiator hose. Service and Repair

22. Disconnect the water hose. Service and Repair

23. Disconnect the ATF oil cooler hose.

24. Disconnect the plastic fuel hose. Before Service Precaution Service and Repair

25. Disconnect the wiring harness.
NOTE:
- Do not disconnect the engine side of this wiring harness.

26. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way. Service and Repair

27. Remove the engine and transaxle component using an engine jack in the order indicated in the figure.

28. Install in the reverse order of removal.

29. Start the engine and:
a. Inspect the runout and contact on the pulley and belt.

b. Inspect for engine oil, engine coolant, ATF, power steering fluid and fuel leakage.

c. Verify the ignition timing, idle speed and idle mixture. Testing and Inspection

d. Engine accessories operation

30. Perform a road test.

NOTE:
- If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no malfunction.










No.1 Engine Mount Removal Note

1. Remove the front under cover A and front under cover B. Front Under Cover Removal/Installation

2. Remove the transverse member. Transverse Member Removal/Installation

3. Remove the intermediate shaft installation bolt, and disconnect the steering shaft. Service and Repair

4. Remove the No.1 engine mounting bracket bolts.






5. Remove the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit. Front Crossmember Removal/Installation






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

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






CAUTION:
- Remove the engine and transaxle carefully, holding it steady. If the transaxle falls it could be damaged or cause injury.

2. Secure the engine, transaxle, and crossmember component using a hoist.

Engine and Transaxle Removal Note

NOTE:
- When lowering the engine, slightly move it to the left side of the vehicle to set the A/C compressor out of the way.






Engine Mount Installation Note

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






Tightening torque
- 15.7-23.5 Nm {1.61-2.39 kgf-m, 11.6-17.3 ft-lbf}

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






3. Temporarily tighten the No.3 engine mount bolt and nuts in the order shown in the figure.






4. Temporarily tighten the No. 4 engine mount bracket in two passes.
a. Temporarily tighten the No.4 engine mount bracket in the order shown in the figure until the flange surface does not adhere.






b. Temporarily tighten the No.4 engine mount bracket in the order shown in the figure until the flange surface firmly adheres.






5. Install the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit. Front Crossmember Removal/Installation






6. Tighten the No.1 engine mount bracket bolt A and B in order of A->B.






Tightening torque
- Bolt A, B: 93.1-116.6 Nm {9.5-11.8 kgf-m, 68.7-85.9 ft-lbf}

NOTE:
- When replacing bolt C on the crossmember side, always replace it with a bolt of the same size as the removed one.

7. Tighten the No.1 engine mount bolt C at the specified torque.






Tightening torque
- M12 bolt: 93.1-116.6 Nm {9.5-11.8 kgf-m, 68.7-85.9 ft-lbf}
- M14 bolt: 104.2-132.6 Nm {10.6-13.5 kgf-m, 76.9-97.8 ft-lbf}

8. Install the intermediate shaft installation bolt, and disconnect the steering shaft. Service and Repair

9. Install the transverse member. Transverse Member Removal/Installation

10. Install the front under cover A and front under cover B. Front Under Cover Removal/Installation

11. Tighten the No.3 engine mount in the order shown in the figure.





Tightening Torque





12. Tighten the No.3 engine mount stay (No.3 engine mount side).

Tightening torque
- 43.1-60.7 Nm {4.40-6.18 kgf-m, 31.8-44.7 ft-lbf}

13. Tighten the No.4 engine mount in the order shown in the figure.





Tightening Torque