REMOVAL AND INSTALLATION


caution *: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body.
Pre-removal Operation
  • Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) <Except for Hong Kong and Singapore> ].
  • Fuel Line Pressure Reduction [Refer to GROUP 13B, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) <Vehicles for Hong Kong and Singapore> ].
  • Engine side cover Removal.
  • Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).
  • Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).
  • Transmission Oil Draining (Refer to GROUP 22A, On-vehicle Service - Transmission Oil Replacement ).
  • Exhaust Pre-muffler Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
  • Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
  • Hood Removal (Refer to GROUP 42, Hood <Except for Hong Kong and Singapore> ).
  • Hood Removal (Refer to GROUP 42, Hood <Vehicles for Hong Kong and Singapore> ).
  • Engine Cover Removal (Refer to ).
  • Air Cleaner Removal (Refer to GROUP 15, Air Cleaner ).
  • Battery and Battery Tray Removal.

 Post-installation Operation
  • Battery and Battery Tray Installation
  • Air Cleaner Installation (Refer to GROUP 15, Air Cleaner ).
  • Engine Cover Installation (Refer to ).
  • Hood Installation (Refer to GROUP 42, Hood <Except for Hong Kong and Singapore> ).
  • Hood Installation (Refer to GROUP 42, Hood <Vehicles for Hong Kong and Singapore> ).
  • Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
  • Exhaust Pre-muffler Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
  • Transmission Oil Refilling (Refer to GROUP 22A, On-vehicle Service - Transmission Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).
  • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).
  • Fuel Leak Check
  • Drive Belt Tension Check (Refer to ).
  • Engine side cover Installation.




Removal steps


1.
 Control wiring harness connection


2.
 Battery wiring harness connection


3.
 Canister vacuum hose connection

>>F<<
 4.
 Brake booster vacuum hose connection


5.
 Power steering oil pressure sensor connector
<<A>>
6.
 Drive belt




Removal steps
<<B>>
7.
 Power steering oil pump and bracket assembly
<<C>>
8.
 A/C compressor and clutch assembly


9.
 Exhaust manifold (Refer to GROUP 15, Exhaust Manifold )


10.
 Alternator assembly (Refer to GROUP 16, Charging System, Alternator Assembly )
<<D>>
11.
 ATF warmer (A/T oil cooler) & bracket assembly <Vehicles with ATF warmer (A/T oil cooler) >


12.
 Heater water hoses connection


13.
 Fuel return line hose connection
<<E>>
 >>E<<
 14.
 Fuel high-pressure hose connection
<<F>>
 >>D<<
 ·
 Transmission assembly
<<G>>
 >>C<<
 ·
 Radiator assembly


15.
 Earth cable connection


16.
 Self-locking nuts
<<H>>
 >>B<<
 17.
 Engine mounting insulator
<<I>>
 >>A<<
 18.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> DRIVE BELT REMOVAL
The following operations will be needed due to the introduction of the serpentine drive system with the drive belt auto-tensioner.

1.Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner.
2.Rotate the auto-tensioner anti-clockwise and align hole A with hole B.

3.
caution To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Insert an L-shaped hexagon wrench, etc. into the hole to fix and then remove the drive belt.

<<B>> POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump and bracket assembly from the engine assembly.
2.After removing the power steering oil pump and bracket assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<C>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1.With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2.After removing the A/C compressor and clutch assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<D>> ATF WARMER (A/T OIL COOLER) & BRACKET ASSEMBLY REMOVAL < VEHICLES WITH ATF WARMER (A/T OIL COOLER) >
With the hose installed, remove the ATF warmer & bracket assembly from the transmission case front roll stopper bracket.

<<E>> FUEL HIGH-PRESSURE HOSE REMOVAL

1.Remove the fuel high-pressure hose stopper.

2.Remove the fuel high-pressure hose in the direction shown in the figure while the retainer is pulled up.
note If the retainer is released, install it after removing the fuel high-pressure hose.

<<F>> TRANSMISSION ASSEMBLY REMOVAL

caution M/T: Do not remove the flywheel bolt. If this bolt is removed, the flywheel assembly will become out of balance and damaged.
Remove the transmission assembly (M/T: Refer to GROUP 22A, Transmission Assembly , A/T: Refer to GROUP 23A, Transmission Assembly ).

<<G>> RADIATOR ASSEMBLY REMOVAL
1.Place a garage jack against the engine oil pan with a piece of wood in between and support the engine assembly.


2.Remove the following special tool.
(1) <Special tool engine hanger (MB991928) is used>
.....1. Remove special tool MB991928.
(2) <Special tool engine hanger (MB991895) is used>
.....1. Remove special tool MB991895.

3.Hold the engine assembly with a chain block, etc.
4.Remove the radiator. (Refer to GROUP 14, Radiator )

<<H>> ENGINE MOUNTING INSULATOR REMOVAL
Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine is not applied to the engine mounting insulator and remove the engine mounting insulator.

<<I>> ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the chain block slowly to remove the engine assembly downwards from the engine compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION
Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

>>B<< ENGINE MOUNTING INSULATOR INSTALLATION
Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mounting insulator while adjusting the position of the engine.

>>C<< RADIATOR ASSEMBLY INSTALLATION
1.Install the radiator assembly. (Refer to GROUP 14, Radiator )
2.Place a garage jack against the engine oil pan with a piece of wood in between and support the engine assembly.
3.Remove the chain block.


4.Use the following special tool as during removal to support the engine assembly.
(1) <Special tool engine hanger (MB991928) is used>
.....1. Set special tool MB991928. (M/T: Refer to GROUP 22A, Transmission Assembly , A/T: Refer to GROUP 23A, Transmission Assembly ).
(2) <Special tool engine hanger (MB991895) is used>
.....1. Set special tool MB991895 (M/T: Refer to GROUP 22A, Transmission Assembly , A/T: Refer to GROUP 23A, Transmission Assembly ).

>>D<< TRANSMISSION ASSEMBLY INSTALLATION
1.Install the transmission assembly (M/T: Refer to GROUP 22A, Transmission Assembly , A/T: Refer to GROUP 23A, Transmission Assembly ).

>>E<< FUEL HIGH-PRESSURE HOSE INSTALLATION


caution After connecting the fuel high-pressure hose, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm. Then install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe and then install the fuel high-pressure hose.

>>F<< BRAKE BOOSTER VACUUM HOSE INSTALLATION

1.Insert the brake booster vacuum hose thoroughly until it contacts the inlet manifold so that its mating mark faces towards the direction shown.
2.Secure the brake booster vacuum hose with hose clip.