Protege 1999-2000

Engine

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Removal & Installation



1.6L (Zm) Engine

NOTE
The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recommended.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the transaxle fluid.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Battery
     
    Air cleaner, air hose and resonance chamber
     
    Front exhaust pipe
     
    Accelerator cable and bracket
     
    Heater and vacuum hoses
     
    Radiator
     
    Drive belt
     
    Fuel hoses
     
    Any rods, pipes or cables related to the transaxle that would hinder removal
     
    Halfshafts
     
    Power steering pump with the lines still attached and set aside
     
    A/C compressor with the lines still attached and position aside
     
    Air cleaner bracket
     
    Battery carrier bracket
     

  12.  
  13. Support the engine with a suitable engine support device.

    Number 1 engine mount. Refer to the accompanying illustration for location.
     
    Number 2 engine mount nut A . Refer to the accompanying illustration for location.
     
    Engine mount member retainers. Refer to the accompanying illustration for location.
     
    Number 2 engine mount. Refer to the accompanying illustration for location.
     

  14.  
  15. Remove the engine support device and attach a hoist and chain to the engine.

    Number 4 engine mount. Refer to the accompanying illustration for location.
     
    Number 3 engine mount. Refer to the accompanying illustration for location.
     
    Engine and transaxle assembly from the vehicle.

    Click image to see an enlarged view

    Fig. Location of the engine mounting components and their torque specifications-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Remove the number 2 engine mount nut retainers A, then the engine mount retainers-Protégé models equipped with the 1.6L (ZM) engine

     

  16.  

To install:

  1. Installation is the reverse of removal. Tighten the fasteners to the specifications shown in the accompanying illustration.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmission assembly in the vehicle.
  4.  
  5. Install or connect the following:

    Tighten the number 3 engine mount bolt and nut in the sequence illustrated, then tighten the mount stay bolt and nut A . Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration.

    Click image to see an enlarged view

    Fig. Tighten the number 3 engine mount bolt and nut in this sequence and the mount stay bolt A-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Number 4 engine mount retainer torque sequence on models with a manual transaxle-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Number 4 engine mount retainer torque sequence on models with a automatic transaxle-Protégé models equipped with the 1.6L (ZM) engine



    Click image to see an enlarged view

    Fig. Number 1 engine mount retainer torque sequence-Protégé models equipped with the 1.6L (ZM) engine

     
    Tighten the number 4 engine mount bolts A , then tighten bolts B . Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration.
     

  6.  
  7. Remove the hoist and chain and install the engine support device.

    Number 2 engine mount nut A , then tighten the mount member bolt and nut. Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration.
     
    Number 1 engine mount bolts A and then the bolt B . Tighten the fasteners to the specifications shown in the accompanying illustration.
     
    Battery carrier bracket
     
    Air cleaner bracket
     
    A/C compressor
     
    Power steering pump
     
    Halfshafts
     
    Any rods, pipes or cables related to the transaxle that were removal
     
    Fuel hoses
     
    Drive belt
     
    Radiator
     
    Heater and vacuum hoses
     
    Accelerator cable and bracket
     
    Front exhaust pipe
     
    Air cleaner, air hose and resonance chamber
     
    Battery
     

  8.  
  9. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system.
  10.  
  11. Connect the negative battery cable, start the engine and check for leaks.
  12.  
  13. Check the ignition timing and the idle speed.
  14.  
  15. Check all fluid levels.
  16.  

 
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