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

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 Fuel Line Safety Procedures.)

1. Disconnect the negative battery cable.

2. Drain the engine coolant, engine oil, and transaxle oil.

3. Remove the radiator. (See RADIATOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

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

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

6. Disconnect the fuel hose. (See BEFORE REPAIR PROCEDURE [MZR-CD (RF Turbo)].)

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

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

9. Remove the shift cable, select cable and clutch release cylinder related to the transaxle. (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [A26M-R].)

10. Remove the clutch release cylinder. (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)

11. Remove the vacuum hose and the heater hose.

12. Disconnect the P/S oil pump pressure pipe and P/S oil pump relief hose from the P/S oil pump side. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

Note

• The P/S oil pump will not be removed from the engine.

13. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. Use wire or rope to secure it. (See A/C COMPRESSOR REMOVAL/INSTALLATION [MZR-CD (RF Turbo)].)

14. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)

15. Remove the front drive shaft (LH) from the transaxle. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)

16. Remove in the order indicated in the table.

17. Install in the reverse order of removal.

18. Fill the engine coolant, engine oil, and transaxle oil.

19. Bleed the air from the fuel line. (See AFTER REPAIR PROCEDURE [MZR-CD (RF Turbo)].)

20. Start the engine and:

• Inspect the pulleys and the drive belt for runout and contact.

• Inspect the engine oil, engine coolant transaxle oil, P/S fluid, and fuel for leakage.

• Inspect the idle speed. (See ENGINE TUNE-UP [MZR-CD (RF Turbo)].)

21. Perform a road test.

22. Reinspect the engine oil, engine coolant, transaxle oil, and P/S fluid levels.

No.1 Engine Mount Rubber Removal Note

1. Remove through-bolt A on the No.1 engine mount bracket side.

2. Loosen through-bolt B on the front crossmember side until approximately three pitches are showing.

Note

• Do not remove the No.1 engine mount rubber from the front crossmember.

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

1. Install the SST using the following procedure.

(1) Align the rear support rod hole to the bolt on the shock absorber as shown in the figure.

(2) Align the front support rod hole to the bolt of the front side frame as shown in the figure.

2. Support the engine using the SST.

Note

• The SST (49E 017 5A0) can be used in place of the SST (49C 017 5A0).

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

4. Remove the SST.

5. Secure the engine and the transaxle using a hoist.

6. Remove the No.4 engine mount bracket and engine mount rubber together as a unit.

No.3 Engine Joint Bracket Installation Note

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

2. Install the SST using the following procedure.

(1) Align the rear support rod hole to the bolt on the shock absorber as shown in the figure.

(2) Align the front support rod hole to the bolt of the front side frame as shown in the figure.

3. Support the engine using the SST.

Note

• The SST (49E 017 5A0) can be used in place of the SST (49C 017 5A0).

4. Tighten the No.3 engine mount bracket stud bolt.

Tightening torque

7.0-13.0 N·m {72-132 kgf·cm, 62-115 in·lbf}

5. Tighten the No.3 engine joint bracket bolt and nut in the order as shown.

Tightening torque

74.5-104.9 N·m {7.6-10.6 kgf·m, 55.0-73.3 ft·lbf}

No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note

1. Tighten the No.4 engine mount bracket and No.4 engine mount rubber bolt and nut in the order as shown.

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

3. Remove the hoist and secure the engine and transaxle using SST.

No.1 Engine Mount Bracket Installation Note

1. Tighten No.1 engine mount bracket bolt A.

Tightening torque

93.1-116.6 N·m {9.5-11.8 kgf·m, 68.7-85.9 ft·lbf}

2. Tighten No.1 engine mount bracket bolt B.

Tightening torque

93.1-116.6 N·m {9.5-11.8 kgf·m, 68.7-85.9 ft·lbf}

No.1 Engine Mount Rubber Installation Note

1. Tighten through-bolt A on the No.1 engine mount bracket.

Tightening torque

85.3-116.6 N·m {8.7-11.8 kgf·m, 63.0-85.9 ft·lbf}

2. Tighten through-bolt B on the front crossmember side.

Tightening torque

93.1-116.6 N·m {9.5-11.8 kgf·m, 68.7-85.9 ft·lbf}