REMOVAL AND INSTALLATION


Pre-removal Operation
  • Hood Removal (Refer to GROUP 42 - Hood ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Oil Draining <4M4> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Air Cleaner Assembly and Air Intake Duct Removal <4M4> (Refer to GROUP 15 - Air Cleaner ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Cooling Fan Clutch Removal <4M4> (Refer to GROUP 14 - Radiator Fan ).
  • Intercooler Removal (Refer to GROUP 15 - Intercooler ).
  • Fuel Filter Assembly Removal <4M40> (Refer to GROUP 13E - Fuel Filter ).

 Post-installation Operation
  • Fuel Filter Assembly Installation <4M40> (Refer to GROUP 13E - Fuel Filter ).
  • Intercooler Installation (Refer to GROUP 15 - Intercooler <4M40> ).
  • Cooling Fan and Cooling Fan Clutch Installation (Refer to GROUP 14 - Radiator Fan ).
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Air Cleaner Assembly and Air Intake Duct Installation <4M4> (Refer to GROUP 15 - Air Cleaner ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Refilling <4M4> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • A/C Compressor Drive Belt Tension Check and Adjustment (Refer to ).
  • Fuel Line Air-bleeding (Refer to GROUP 13C - On-vehicle Service, Evacuation of Air From Fuel Line ).
  • Accelerator Cable Adjustment (Refer to GROUP 17 - Engine Control, On-vehicle Service, Accelerator Cable Check and Adjustment ).
  • Under Skid Plate and Engine Room Under Cover (Front) Installation (Refer to GROUP 51 - Under Cover ).
  • Hood Installation (Refer to GROUP 42 - Hood ).




Removal steps


1.
 Control wiring harness connection


2.
 Battery cable connection


3.
 Earth terminal connection


4.
 A/T fluid level gauge and guide assembly <A/T>


5.
 O-ring <A/T>


6.
 Accelerator cable connection




Removal steps


7.
 Brake booster vacuum hose connection <L.H. drive vehicles without ABS>


8.
 Brake booster vacuum hose connection <R.H. drive vehicles without ABS>


9.
 Freewheel clutch vacuum hose connection
<<A>>
10.
 Power steering oil pump assembly


11.
 O-ring
<<B>>
12.
 A/C compressor drive belt
<<C>>
13.
 A/C compressor assembly


14.
 A/C compressor bracket


15.
 Heater hose connection


16.
 Fuel return hose connection


·
 Starter assembly <4M4> (Refer to GROUP 16 - Starter motor ).


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


·
 Transmission assembly (Refer to GROUP 23A - Transmission assembly ) <A/T>.
<<D>>
17.
 Engine mounting insulator bolt
<<D>>
 >>A<<
 18.
 Engine assembly

REMOVAL SERVICE POINTS

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

<<B>> A/C COMPRESSOR DRIVE BELT REMOVAL

1.Loosen the locking nut of the tensioner pulley.
2.
caution To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Rotate the adjusting bolt to the anti-clockwise direction (to the left), and remove the drive belt.

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

<<D>> ENGINE MOUNTING INSULATOR BOLT/ENGINE ASSEMBLY REMOVAL

1.Using special tool sling chain set (MB991683), lift the engine assembly up to where no load is applied to the engine mounting insulator.
2.Remove the engine mounting insulator bolts.
3.Check that all cables, hoses and wiring harness connectors are disconnected from the engine.
4.Lift special tool (MB991683) and chain block slowly to remove the engine assembly upwards from the engine compartment.

INSTALLATION SERVICE POINT

>>A<< ENGINE ASSEMBLY INSTALLATION

1.Use special tool sling chain set (MB991683) and chain block to lift the engine assembly in the same manner as removal.
2.Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.