REMOVAL AND INSTALLATION


caution 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, Reduce Pressurized Fuel Lines ).
  • Hood Removal (Refer to GROUP 42 - Hood ).
  • Engine Room Under Cover Removal (Refer to GROUP 51 - Under Cover ) <2WD>
  • Under Skid Plate and Engine Room Under Cover Removal (Refer to GROUP 51 - Under Cover ) <4WD>
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Change ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Change ).
  • Transmission Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Change ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Bracket Removal
  • Radiator Assembly Removal (Refer to GROUP 14 - Radiator ).
  • Drive belt Removal (Refer to Crankshaft Pulley ).

 Post-installation Operation
  • Drive belt Installation (Refer to Crankshaft Pulley ).
  • Radiator Assembly Installation (Refer to GROUP 14 - Radiator ).
  • 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 Change ).
  • Transmission Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Change ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Change ).
  • Drive Belt Tension Check (Refer to ).
  • Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover ) <2WD>
  • Under Skid Plate and Engine Room Under Cover Installation (Refer to GROUP 51 - Under Cover ) <4WD>
  • Hood Installation (Refer to GROUP 42 - Hood ).
  • Fuel Leak Check




Removal steps


·
 Control wiring harness connection


·
 Battery wiring harness connection


·
 Earth cable and bracket connection


·
 Brake booster vacuum hose connection (Refer to GROUP 35A - Master Cylinder Assembly and Brake Booster Assembly ) <R.H. drive vehicles>.


·
 Brake booster vacuum hose connection (Refer to GROUP 35A - Master Cylinder Assembly and Brake Booster Assembly ) <L.H. drive vehicles>.


·
 Purge hose connection (Refer to GROUP 17 - Emission Control, Canister ).


·
 Free wheel clutch vacuum hose connection <Vehicles with easy select 4WD> (Refer to GROUP 55 - Compressor Assembly )


·
 A/C compressor drive belt (Refer to )


·
 Power steering oil pump drive belt (Refer to )


·
 A/C compressor assembly (Refer to GROUP 55 - Compressor Assembly )


·
 Power steering oil pump assembly (Refer to GROUP 37 - Power Steering Oil Pump Assembly )


·
 Heater water hose connection (Refer to GROUP 55 - Heater Hose )


·
 Fuel main pipe connection (Refer to GROUP 13A - Injector ).


·
 Front exhaust pipe connection (Refer to GROUP 15 - Exhaust Pipe and Main Muffler )


·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <2WD>.


·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <4WD>.


1.
 Engine support front insulator mounting bolt
<<A>>
 >>A<<
 2.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> ENGINE ASSEMBLY REMOVAL
1.Check that all cables, hoses and wiring harness connectors are disconnected from the engine

2.Lift the special tools hanger (MB991527) and engine hanger balancer (MB991454) slowly to remove the engine assembly upwards from the engine compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION

1.Use special tools hanger (MB991527) and engine hanger balancer (MB991454) 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.