REMOVAL AND INSTALLATION


caution When the engine assembly is replaced, initialise the learned value using M.U.T.-III (Refer to GROUP 00 - Precautions before Service, and Initialisation Procedure of MPI Engine Learned Value ).
Pre-removal operation
  • Hood Removal (Refer to GROUP 42A - Hood ).
  • Fuel Line Pressure Reduction [Refer to GROUP 13A - On-vehicle Service, Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].
  • Engine Room Under Cover Front A, B and Engine Room Side Cover Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Transmission Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Change ) <M/T>.
  • Transmission Fluid Draining (Refer to GROUP 23A - On-vehicle Service, Essential Service, CVT Fluid Change ) <CVT>.
  • Engine Cover Removal (Refer to ).
  • Air Cleaner Intake Hose and Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Engine-ECU Removal (Refer to GROUP 13B - Engine-ECU ).
  • Strut Tower Bar Removal (Refer to GROUP 42A - Strut Tower Bar ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).

 Post-installation operation
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Strut Tower Bar Installation (Refer to GROUP 42A - Strut Tower Bar ).
  • Engine-ECU Installation (Refer to GROUP 13B - Engine-ECU ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Intake Hose and Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Cover Installation (Refer to ).
  • Transmission Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Change ) <M/T>.
  • Transmission Fluid Refilling (Refer to GROUP 23A - On-vehicle Service, Essential Service, CVT Fluid Change ) <CVT>.
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Alternator and Others Belt Tension Check (Refer to ).
  • Engine Room Under Cover Front A, B and Engine Room Side Cover Installation (Refer to GROUP 51 - Under Cover ).
  • Fuel Leak Check
  • Hood Installation (Refer to GROUP 42A - Hood ).




Removal steps
<<A>>
·
 Cowl top panel (Refer to GROUP 42A - Loose Panel )


1.
 Control wiring harness connection


2.
 Battery cable connection


3.
 Heater hose connection


4.
 Canister vacuum hose connection


5.
 Brake booster vacuum hose connection


6.
 Cooling water line hose connection
<<B>>
 >>D<<
 7.
 Fuel high-pressure hose connection


·
 Alternator and others belt (Refer to )




Removal steps
<<C>>
8.
 Power steering oil pump assembly
<<D>>
 >>C<<
 9.
 A/C compressor and clutch assembly
<<E>>
·
 Transmission assembly <M/T> (Refer to GROUP 22A - Transmission Assembly )
<<E>>
·
 Transmission assembly <CVT> (Refer to GROUP 23A - Transmission Assembly )


10.
 Earth cable connection
<<F>>
 >>B<<
 11.
 Engine mounting insulator
<<G>>
 >>A<<
 12.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> COWL TOP PANEL REMOVAL
caution After removing the cowl top panel, perform operation with care not to damage the windshield.
After removing the cowl top panel, attach a protection tape for the windshield on the lower area of the windshield.

<<B>> FUEL HIGH-PRESSURE HOSE REMOVAL

1.Remove the stopper of the fuel high-pressure hose.

2.Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.
note If the retainer is released, install it securely after removing the fuel high-pressure hose.

<<C>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump assembly from the bracket.
2.Tie the removed power steering oil pump with a string at a position where it will not interfere with the removal and installation of engine assembly.

<<D>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1.Remove the A/C compressor and clutch assembly together with the hose from the bracket.
2.Tie the removed A/C compressor and clutch assembly with a string at a position where they will not interfere with the removal and installation of engine assembly.

<<E>> TRANSMISSION ASSEMBLY REMOVAL

1.Install the headlamp support panel upper bolts to the position as shown in the figure.
2.Remove the transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <M/T> or (Refer to GROUP 23A - Transmission Assembly ) <CVT>.

<<F>> ENGINE MOUNTING INSULATOR REMOVAL
1.
caution When supporting the engine and transmission assembly with a garage jack, be careful not to deform the engine oil pan.
Place a garage jack against the engine oil pan with a piece of wood in between to support the engine assembly.



2.Remove special tools engine hanger (MB991928 or MB991895) and engine hanger plate (MB992201) which was installed for supporting the engine assembly when the transmission assembly was removed (Refer to GROUP 22A - Transmission Assembly ) <M/T> or (Refer to GROUP 23A - Transmission Assembly ) <CVT>.
3.Operate a garage jack so that the engine weight is not applied to the engine mounting insulator, and remove the engine mounting insulator.

<<G>> ENGINE ASSEMBLY REMOVAL

1.Mount the special tool engine hanger balancer (MB991454) to the power steering oil pump bracket and the engine hanger, and set the chain block.
2.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

Install the engine assembly, being careful not to pinch the cables, hoses, or wiring harness connectors.

>>B<< ENGINE MOUNTING INSULATOR INSTALLATION
1.
caution When supporting the engine and transmission assembly with a garage jack, be careful not to deform the engine oil pan.
Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine mounting insulator while adjusting the position of the engine assembly.
2.Remove special tool engine hanger balancer (MB991454).



3.Install special tools engine hanger plate (MB992201) and engine hanger (MB991928 or MB991895) which is used during installation of transmission assembly to hold the engine assembly (Refer to GROUP 22A - Transmission Assembly ) <M/T> or (Refer to GROUP 23A - Transmission Assembly ) <CVT>.
4.Remove the garage jack which supports the engine assembly.

>>C<< A/C COMPRESSOR AND CLUTCH ASSEMBLY INSTALLATION

Tighten A/C compressor and clutch assembly mounting bolts to the specified torque in the order of number shown in the illustration.
Tightening torque: 23 ± 6 N·m

>>D<< FUEL HIGH-PRESSURE HOSE INSTALLATION
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. After the check, install the stopper securely.


Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.