REMOVAL AND INSTALLATION


caution When the engine assembly is replaced, register the injector identification code, perform the small injection quantity learning and perform the supply pump correction learning (Refer to GROUP 00 - Precautions before Service, What the Common Rail Engine Learns ).
Pre-removal Operation
  • Hood Removal (Refer to GROUP 42A - Hood ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery Tray Stay Removal (Refer to GROUP 54A - Battery ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Fan Clutch Assembly Removal (Refer to GROUP 14 - Cooling Fan ).

 Post-installation Operation
  • Cooling Fan and Fan Clutch Assembly Installation (Refer to GROUP 14 - Cooling Fan ).
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Battery Tray Stay Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Bleeding from Fuel Line.
  • Hood Installation (Refer to GROUP 42A - Hood ).




Removal steps

>>B<<
 1.
 Engine cover


2.
 Injector upper insulator


3.
 Injector lower insulator


4.
 Common rail insulator


·
 Freewheel clutch vacuum hose connection (Refer to GROUP 26 - Solenoid Valve and Vacuum Hose ) <Vehicles with freewheel clutch>.


·
 Control wiring harness connection


·
 Battery wiring harness connection (positive battery terminal) (Refer to GROUP 54A - Battery ).
<<A>>
·
 Power steering oil pump assembly (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).
<<B>>
·
 A/C compressor and clutch assembly (Refer to GROUP 55B - Compressor Assembly ).


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


·
 Heater piping hose connection (Refer to GROUP 55B - Heater Hose ).


·
 Fuel hose D connection (Refer to GROUP 13C - Fuel Injection Pump ).


·
 Fuel return hose connection (Refer to GROUP 13C - Fuel Injection Pump ).


·
 Catalytic converter (Refer to GROUP 17 - Emission Control, Catalytic Converter ).


·
 Starter assembly mounting bolt (Refer to GROUP 16 - Starting System, Starter Assembly ).


·
 Transmission assembly (Refer to GROUP 23A - Transmission Assembly ) <A/T-2WD>.


·
 Transmission assembly (Refer to GROUP 23A - Transmission Assembly ) <A/T-4WD>.
<<C>>
5.
 Engine mounting bolt
<<C>>
 >>A<<
 6.
 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 bracket.
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>> ENGINE MOUNTING BOLT/ENGINE ASSEMBLY REMOVAL


1.Install special tool engine hanger plate (MB991956) to the cylinder head.

2.Using the chain block, lift the engine assembly up to where no load is applied to the front engine support insulator.
3.Remove the engine mounting bolts.
4.Check that all cables, hoses and wiring harness connectors are disconnected from the engine.
5.Lift the chain block slowly to remove the engine assembly upwards from the engine compartment.
6.Remove the engine assembly, and then remove the starter assembly from the engine assembly.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION
1.Use the 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.

>>B<< ENGINE COVER INSTALLATION

1.Engage the section "A" of the engine cover with the stud on the engine cover bracket.
2.Tighten the mounting bolt "B" loosely enough to slide the engine cover by hand.
3.Tighten the mounting bolts "C" to the specified torque.
Tightening torque: 3.0 ± 0.5 N·m
4.Tighten the mounting bolt "B" to the specified torque.
Tightening torque: 3.0 ± 0.5 N·m