Removal and Replacement

ENGINE REMOVAL/INSTALLATION [MZR 2.5]

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

NOTE:
- Perform the engine and transaxle component removal/installation from below the vehicle.

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

2. Remove the plug hole plate. Service and Repair

3. Remove the air hose and air cleaner component. Service and Repair

4. Set the cooler pipe and the cooler hose (LO) out of the way. Service and Repair

5. Disconnect the brake vacuum hose. Service and Repair

6. Remove the front wheels and tires. Service and Repair

7. Set the front mudguards out of the way. Service and Repair

8. Remove the splash shields.

9. Remove the aerodynamic under cover No.1 and No.2. Aerodynamic Under Cover No. 1 Removal/Installation Aerodynamic Under Cover No. 2 Removal/Installation

10. Remove the drive belt. Service and Repair

11. Remove the TWC. Service and Repair

12. Drain the engine coolant. Service and Repair

13. Remove the coolant reserve tank. Service and Repair

14. Drain the ATF (ATX) or transaxle oil (MTX). (See Automatic Transaxle Fluid (ATF) Replacement (ATX).) (See Transaxle Oil Replacement (MTX).)

15. Disconnect the drive shafts from the engine side, set the drive shafts out of the way. Drive Shaft Removal/Installation

16. Disconnect the radiator hose. Service and Repair

17. Disconnect the vacuum hose and the heater hose.

18. Disconnect the oil hose, selector cable, and wiring harness. (ATX) Automatic Transaxle Removal/Installation

19. Disconnect the shift cable and wiring harness. (MTX) Manual Transaxle Removal/Installation

20. Remove the clutch release cylinder with the pipe still connected. (MTX) Removal and Replacement

21. Disconnect the fuel hose. Quick Release Connector Removal/Installation

22. Remove the A/C compressor with the pipes still connected. Service and Repair

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






24. Disconnect the wiring harness from the engine side.

25. Remove in the order indicated in the table.

26. Install in the reverse order of removal.

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

- Leakage of engine oil, engine coolant, ATF, transaxle oil, and fuel.
- Runout and contact of pulley and belt.
- Verify the ignition timing, idle speed and idle mixture. Service and Repair
- 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.









No.1 Engine Mount Removal Note

NOTE:
- Remove the No.1 engine mount rubber and the front crossmember as a single unit. Front Suspension - Crossmember Removal/Installation

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

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






Engine Mount Installation 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.






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

Tightening torque
- 77-103 Nm {7.9-10 kgf-m, 57-75 ft-lbf}

NOTE:
- If the No.3 engine mount bracket and the engine are removed, retighten the No.3 engine mount stud bolts.

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






Tightening torque
- 7-13 Nm {72-132 kgf-cm, 62-115 in-lbf}

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






6. Temporarily tighten the No.3 engine mount bolt and nuts.

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






Tightening torque
- 75-104 Nm {7.7-10 kgf-m, 56-76 ft-lbf}

8. Temporarily tighten the No.4 engine mount bolts.

9. Tighten the No.4 engine mount bolts.






Tightening torque
- 77-103 Nm {7.9-10 kgf-m, 57-75 ft-lbf}

10. Tighten the bolt D.






Tightening torque
- 77-103 Nm {7.9-10 kgf-m, 57-75 ft-lbf}

11. Tighten the bolt A.






Tightening torque
- 94-116 Nm {9.6-11 kgf-m, 70-85 ft-lbf}