REMOVAL AND INSTALLATION


caution
  • *: Indicates parts which should be initially tightened, and then fully tightened after placing the vehicle horizontally and loading the full weight of the engine on the vehicle body.
  • When the engine assembly replacement is performed, use the M.U.T.-III to initialise the learning value (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, Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].
  • Hood Removal (Refer to GROUP 42 - Hood ).
  • Under Skid Plate and Engine Room Under Cover (Front) Removal (Refer to GROUP 51 - Under Cover ).
  • 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 ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Bracket Removal
  • Cooling Fan and Cooling Fan Clutch Assembly Removal (Refer to GROUP 14 - Cooling Fan ).
  • Radiator Assembly Removal (Refer to GROUP 14 - Radiator ).
  • Front Exhaust Pipe Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).

 Post-installation Operation
  • Front Exhaust Pipe Installation (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • Radiator Assembly Installation (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Cooling Fan Clutch Assembly Installation (Refer to GROUP 14 - Cooling Fan ).
  • Battery and Battery Tray Bracket Installation
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • 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 ).
  • Drive Belt Tension Check (Refer to ).
  • Under Skid Plate and Engine Room Under Cover (Front) Installation (Refer to GROUP 51 - Under Cover ).
  • Hood Installation (Refer to GROUP 42 - Hood ).
  • Fuel Leak Check




Removal steps


1.
 Engine cover


2.
 Canister vacuum hose connection


3.
 Freewheel clutch vacuum hose connection


4.
 Earth cable connection


5.
 Control wiring harness


6.
 Battery wiring harness




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


9.
 Engine oil cooler hose


10.
 Gasket


11.
 A/C compressor bracket
<<C>>
 >>B<<
 12.
 Fuel high-pressure hose connection


·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly ).


·
 Transmission assembly (Refer to GROUP 23A - Transmission Assembly ).


13.
 Heater hose connection
<<D>>
 >>A<<
 14.
 Engine mounting bracket connecting bolts
<<D>>
 >>A<<
 15.
 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 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.

<<C>> FUEL HIGH-PRESSURE HOSE DISCONNECTION


1.
caution Be careful not to twist the fuel high-pressure hose because it is made of resin.
Disconnect the fuel high-pressure hose on the fuel pipe side according to the following procedures.
(1) Remove the stopper of the fuel high-pressure hose.
(2) While pulling up the retainer of the fuel high-pressure hose, remove the fuel high-pressure hose in the direction as shown.
note If the retainer is released, install it securely after removing the fuel high-pressure hose.


2.Disconnect the fuel high-pressure hose on the fuel delivery pipe side according to the following procedures.
(1) Insert the flat-tipped screwdriver or similar tool (width: 6 mm, thickness: 1 mm) to the retainer of the fuel high-pressure hose connector.
(2) Turn the flat-tipped screwdriver inserted into the retainer by 90 degrees, push up the retainer, and then unlock the fuel high-pressure hose connector.
(3) Disconnect the fuel high-pressure hose from the fuel delivery pipe.
3.Remove the fuel high-pressure hose from the engine assembly.

<<D>> ENGINE ASSEMBLY REMOVAL

1.Using the special tool engine hanger balancer (MB991454) and chain block, hold the engine assembly.

2.Remove the wood chip inserted in between the oil pan and the crossmember No. 2 to hold the engine assembly when the transmission assembly is removed.
3.Remove the engine mounting bracket connecting bolts, and disconnect the engine mounting bracket and the crossmember No. 1.
4.After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the engine assembly slowly with the chain block to remove the engine assembly upward from the engine compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION

1.Set the special tool engine hanger balancer (MB991454) and chain block to the engine assembly.
2.Install the engine assembly, being careful not to pinch the cables, hoses, or wiring harness connectors.
3.
caution Tighten the engine mounting bracket mounting bolt to the specified torque with the engine weight applied on the vehicle body after the engine installation.
Align the bolt hole of engine mounting bracket with the screw hole of the crossmember No. 1, and temporarily tighten the engine mounting bracket mounting bolt.

4.Install the wood chip inserted in between the oil pan and the crossmember No. 2 to hold the engine assembly when the transmission assembly is removed.
5.Remove the special tool and chain block.

>>B<< FUEL HIGH-PRESSURE HOSE CONNECTION


1.
caution Be careful not to twist the fuel high-pressure hose because it is made of resin.
Connect the fuel high-pressure hose on the fuel delivery pipe side according to the following procedures.
(1) Before connecting the fuel high-pressure hose to the fuel deliver pipe, press up the retainer of the fuel high-pressure hose connector, and unlock the fuel high-pressure hose connector.
(2)
caution After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 1-mm play.
Insert the fuel high-pressure hose to the fuel delivery pipe, press down the retainer, and then lock the fuel high-pressure hose connector.


2.Connect the fuel high-pressure hose on the fuel pipe side according to the following procedures.
(1)
caution After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 3-mm play. Then install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.
3.Install the fuel high-pressure hose to the engine assembly.