REMOVAL AND INSTALLATION


Pre-removal Operation
  • Hood Removal (Refer to GROUP 42 - Hood ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • 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 - Cooling Fan ).
  • Intercooler Removal (Refer to GROUP 15 - Intercooler ).
  • Fuel Filter Assembly Removal <4M41> (Refer to GROUP 13E - Fuel Filter ).

 Post-installation Operation
  • Fuel Filter Assembly Installation <4M41> (Refer to GROUP 13E - Fuel Filter ).
  • Intercooler Installation (Refer to GROUP 15 - Intercooler ).
  • Cooling Fan and Cooling Fan Clutch Installation <4M4> (Refer to GROUP 14 - Cooling 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 13D - On-vehicle Service, Evacuation of Air From Fuel Line ).
  • 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.
 Engine cover


2.
 Bracket


3.
 Earth terminal connection


4.
 Vacuum hose connection


5.
 Fuel cover


6.
 Control wiring harness connection


7.
 Battery cable connection




Removal steps


8.
 Vacuum hose connection
<<A>>
9.
 A/C compressor drive belt
<<B>>
10.
 Power steering oil pump assembly
<<C>>
11.
 A/C compressor assembly


12.
 A/C compressor bracket


13.
 Heater hose connection


14.
 Fuel return hose connection


15.
 Fuel 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>>
16.
 Engine mounting bolt
<<D>>
 >>A<<
 17.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> 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.

<<B>> 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.

<<C>> A/C COMPRESSOR ASSEMBLY REMOVAL
1.With the hose installed, remove the A/C compressor assembly from the 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 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.
2.Remove the engine mounting 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.