REMOVAL AND INSTALLATION


caution When the engine assembly is replaced, initialise the learned value using M.U.T.-III (Refer to GROUP 00 - Precautions before Service, Initialisation Procedure for Learning Value in MPI Engine ).
Pre-removal Operation
  • Fuel Line Pressure Reduction (Refer to GROUP 13A - On-vehicle Service, Reduce Fuel Pressure in Pressurized Fuel Lines ).
  • Engine Room Under Cover Removal (Refer to GROUP 51 - Under Cover <Except vehicles for Thailand>, <Vehicles for Thailand>).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Transmission Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ) <M/T>.
  • CVT Fluid Draining (Refer to GROUP 23A - On-vehicle Service, CVT Fluid Replacement ) <CVT>.
  • Starter Assembly Removal (Refer to GROUP 16 - Starting System, Starter Assembly ).
  • Bell Housing Cover Removal (Refer to ).
  • Drive Shaft Assembly Removal (Refer to GROUP 26 - Drive Shaft Assembly ).
  • Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Radiator Assembly Removal (Refer to GROUP 14 - Radiator ).

 Post-installation Operation
  • Radiator Assembly Installation (Refer to GROUP 14 - Radiator ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold ).
  • Drive Shaft Assembly Installation (Refer to GROUP 26 - Drive Shaft Assembly ).
  • Bell Housing Cover Installation (Refer to ).
  • Starter Assembly Installation (Refer to GROUP 16 - Starting System, Starter Assembly ).
  • Transmission Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ). <M/T>.
  • CVT Fluid Refilling (Refer to GROUP 23A - On-vehicle Service, CVT Fluid Replacement ) <CVT>.
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Fuel Leak Check
  • Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover <Except vehicles for Thailand>, <Vehicles for Thailand>).




Removal steps

>>C<<
 ·
 Control wiring harness connection


·
 Brake booster vacuum hose connection (LHD: Refer to GROUP 35A - Master Cylinder Assembly and Brake Booster Assembly , RHD: Refer to GROUP 35A - Master Cylinder Assembly and Brake Booster Assembly ).


·
 Purge hose connection (Refer to GROUP 17 - Emission Control, Canister ).


·
 Clutch cable connection (Refer to GROUP 21A - Clutch Control ) <M/T>.


·
 Gearshift cable and select cable connection (Refer to GROUP 22A - Transmission Assembly ) <M/T>.


·
 Transmission control cable connection (Refer to GROUP 23A - Transmission Assembly ) <CVT>.


·
 Torque converter and drive plate coupling bolt (Refer to GROUP 23A - Transmission Assembly ) <CVT>.
<<A>>
·
 A/C compressor and clutch assembly (Refer to GROUP 55A - Compressor Assembly ) <Vehicles with A/C and cooler>.


·
 Heater water hose A connection (Refer to ) <Vehicles with A/C and heater>.


·
 Heater water hose B connection (Refer to GROUP 14 - Water Hose and Water Pipe ) <Vehicles with A/C and heater>.


·
 Fuel main pipe connection (Refer to GROUP 13A - Injector ).
<<B>>
 >>B<<
 ·
 Engine mounting insulator (Refer to GROUP 32 - Engine Mounting ).
<<B>>
 >>B<<
 ·
 Transmission mounting insulator (Refer to GROUP 32 - Transmission Mounting ).
<<C>>
 >>A<<
 1.
 Engine and transmission assembly


·
 Transmission assembly coupling bolt (Refer to GROUP 22A - Transmission Assembly ) <M/T>.


·
 Transmission assembly coupling bolt (Refer to GROUP 23A - Transmission Assembly ) <CVT>.


2.
 Transmission assembly


3.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1.Remove the A/C compressor and clutch assembly together with the hose from the bracket.
2.Tie the removed A/C compressor and clutch assembly with a string at a position where they will not interfere with the removal and installation of engine and transmission assembly.

<<B>> ENGINE MOUNTING INSULATOR/TRANSMISSION MOUNTING INSULATOR REMOVAL
1.Secure special tool engine hanger (MB991928 or MB991895) for holding the engine and transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <M/T> or (Refer to GROUP 23A - Transmission Assembly ) <CVT>.
2.Adjust the special tool not to allow the weight of the engine and transmission assembly to rest on the engine mounting insulator and transmission mounting insulator. Then remove the engine mounting insulator and transmission mounting insulator.

<<C>> ENGINE AND TRANSMISSION ASSEMBLY REMOVAL

1.Place special tool EV battery cart (MB992336) below the engine and transmission assembly.
2.
caution When supporting the engine and transmission assembly with special tool, be careful not to deform the oil pan.
Place special tool (MB992336) against the oil pan with a piece of wood in between to support the engine and transmission assembly.
3.Remove special tool engine hanger (MB991928 or MB991895).
4.Confirm that the cable, the hose and the harness connector are all disconnected.
5.
caution Do not bend the fuel main pipe.
Raise the body slowly with a lift, and remove the engine and transmission assembly.

INSTALLATION SERVICE POINTS

>>A<< ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION

Use special tool EV battery cart (MB992336) as during removal to install the engine and transmission assembly.

>>B<< TRANSMISSION MOUNTING INSULATOR/ENGINE MOUNTING INSULATOR INSTALLATION
Use special tool engine hanger (MB991928 or MB991895) as during removal to install the transmission mounting insulator and engine mounting insulator.

>>C<< CONTROL WIRING HARNESS CONNECTION

1.Install the earth terminal to the timing chain case as shown.
2.Tighten the earth terminal mounting bolt to the specified torque.
Tightening torque: 9.0 ± 2.0 N·m