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. Drain the ATF. Automatic Transaxle Fluid (ATF) Replacement [AW6A-EL]
7. Remove the engine cover. Service and Repair
8. Disconnect the purge hose from the dynamic chamber side.
9. Disconnect the vacuum hose. Service and Repair
10. Remove the air cleaner. Service and Repair
11. Remove the aerodynamic under cover No.1. Aerodynamic Under Cover No.1 Removal/Installation
12. Remove the both front wheels and tires. Service and Repair
13. Remove the both front mudguards. Service and Repair
14. Remove the both front splash shields.
15. Remove the generator and A/C drive belt. Service and Repair
16. Disconnect the front drive shaft (RH) from the joint shaft side. Drive Shaft Removal/Installation
17. Disconnect the front drive shaft (LH) from the transaxle side. Drive Shaft Removal/Installation
18. Remove the front pipe. Service and Repair
19. Disconnect the shift cable from the transaxle side. Automatic Transaxle Removal/Installation [AW6A-EL]
20. Disconnect the heater hose. Removal and Replacement
21. Disconnect the power steering oil pump hose out of the way. (See Removal and Replacement.)
22. Disconnect the power steering return hose. Removal and Replacement
23. Disconnect the radiator hose from the engine side. Service and Repair
24. Disconnect the water hose from the thermostat side.
25. Disconnect the ATF oil cooler hose.
26. Disconnect the plastic fuel hose. Before Service Precaution Service and Repair
27. Disconnect the power steering reserve tank out of the way. Removal and Replacement
28. Remove the wiring harness bolt and nuts shown in the figure.
29. Disconnect the wiring harness.
NOTE:
- Do not disconnect the engine side of this wiring harness.
30. 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
31. Remove the engine and transaxle component using an engine jack in the order indicated in the figure.
32. Install in the reverse order of removal.
33. 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. Service and Repair
d. Engine accessories operation.
34. 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 transverse member. Transverse Member Removal/Installation
2. Remove the intermediate shaft bolt, and disconnect the steering shaft. Steering Wheel And Column Removal/Installation [Without Advanced Keyless Entry And Push Button Start System] Steering Wheel And Column Removal/Installation [With Advanced Keyless Entry And Push Button Start System]
3. 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 Bracket and No.4 Engine Mount Bracket Removal Note
1. Secure the engine and transaxle using an engine jack and attachment.
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.
NOTE:
- If the No.3 engine mount bracket and the engine are removed, retighten the No.3 engine mount stud bolts.
Tightening torque
- 16-23 Nm {1.7-2.3 kgf-m, 12-16 ft-lbf}
2. Secure the engine and the transaxle using an engine jack and attachment as shown.
NOTE:
- Temporarily bolt 1 approximately three thread.
3. Temporarily tighten the No.4 engine mount bracket bolt and nuts in the order shown in the figure.
4. Tighten the No.4 engine mount bracket in the order shown in the figure.
Tightening Torque
5. Temporarily tighten the No.3 engine mount bracket bolt and nuts in the order shown in the figure.
6. Tighten the No.3 engine mount bracket in the order shown in the figure.
Tightening Torque
7. Install the No.1 engine mount, No.1 engine mount bracket and the front crossmember as a single unit. Front Crossmember Removal/Installation
8. Install the through bolt A on the front crossmember side until approximately three pitches are showing.
9. Temporarily tighten the No.1 engine mount bracket bolts in the order of B and C.
10. Tighten the No.1 engine mount bracket bolts in the order of B and C.
Tightening torque
- 77-103 Nm {7.9-10 kgf-m, 57-75 ft-lbf}
11. Tighten the No.1 engine mount bolt D.
Tightening torque
- 77-103 Nm {7.9-10 kgf-m, 57-75 ft-lbf}
12. Tighten the bolt A.
Tightening torque
- 94-116 Nm {9.6-11 kgf-m, 70-85 ft-lbf}
13. Install the intermediate shaft bolt, and disconnect the steering shaft. Steering Wheel And Column Removal/Installation [Without Advanced Keyless Entry And Push Button Start System] Steering Wheel And Column Removal/Installation [With Advanced Keyless Entry And Push Button Start System]
14. Install the transverse member. Transverse Member Removal/Installation