REMOVAL AND INSTALLATION


Pre-removal Operation
  • Engine Room Under Cover Front A, B and Engine Room Side Cover Removal (Refer to GROUP 51 - Under Cover ).
  • 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 ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Air Cleaner Removal (Refer to GROUP 15 - Air Cleaner ).
  • Catalytic Converter Removal (Refer to GROUP 17 - Catalytic Converter ). <Vehicles without DPF>
  • DPF Assembly Removal (Refer to GROUP 17 - Diesel Particulate Filter ). <Vehicles with DPF>
  • Intercooler Air Hose A, D, E, Pressure Hose Assembly and Air Pipe A, C, D Removal (Refer to GROUP 15 - Intercooler ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).
  • Strut Tower Bar Removal (Refer to GROUP 42A - Strut Tower Bar ).
  • Hood Removal (Refer to GROUP 42A - Hood ).

 Post-installation Operation
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Intercooler Air Hose A, D, E, Pressure Hose Assembly and Air Pipe A, C, D Installation (Refer to GROUP 15 - Intercooler ).
  • Air Cleaner Installation (Refer to GROUP 15 - Air Cleaner ).
  • Strut Tower Bar Installation (Refer to GROUP 42A - Strut Tower Bar ).
  • Hood Installation (Refer to GROUP 42A - Hood ).
  • Catalytic Converter Removal (Refer to GROUP 17 - Catalytic Converter ). <Vehicles without DPF>
  • DPF Assembly Installation (Refer to GROUP 17 - Diesel Particulate Filter ). <Vehicles with DPF>
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • 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 Replacement ).
  • Drive Belt Tension Check (Refer to ).
  • Fuel Leak Check
  • Engine Room Under Cover Front A, B and Engine Room Side Cover Installation (Refer to GROUP 51 - Under Cover ).




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


1.
 Engine cover


2.
 Control wiring harness connection


3.
 Battery wiring harness connection


4.
 Brake booster vacuum hose connection


5.
 Vacuum hose and pipe assembly
<<B>>
6.
 Drive belt




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


9.
 Heater water hoses connection


10.
 Fuel return line hose connection


11.
 Fuel line hose connection
<<E>>
·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly )
<<F>>
 >>B<
 12.
 Engine mounting insulator
<<G>>
 >>A<<
 13.
 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>> DRIVE BELT REMOVAL
The following operations will be needed due to the introduction of the serpentine drive system with the drive belt auto-tensioner.

1.Rotate the auto-tensioner anti-clockwise and align hole A with hole B.

2.When inserting an L-shaped hexagon wrench, etc. into the hole of the auto-tensioner, insert the wrench into the water draining hole of the side member inner first, and then insert it into the hole of the auto-tensioner.

3.
caution To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Insert an L-shaped hexagon wrench, etc. into the hole to fix the auto-tensioner and then remove the drive belt.

<<C>> POWER STEERING OIL PUMP REMOVAL
1.With the hose installed, remove the power steering oil pump from the bracket.
2.After removing the power steering oil pump, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<D>> A/C COMPRESSOR ASSEMBLY REMOVAL
1.Remove the A/C compressor assembly together with the hose from the bracket.
2.Tie the removed A/C compressor 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 front end upper bar bolts to the position as shown in the figure.
2.Remove the transmission assembly (Refer to GROUP 22A - Transmission Assembly ).

<<F>> ENGINE MOUNTING INSULATOR REMOVAL
1.
caution When supporting the engine 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) which was installed for supporting the engine assembly when the transmission assembly was removed (Refer to GROUP 22A - Transmission Assembly ).
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.Install the special tool engine hanger balancer (MB991454) 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 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 (MB991928 or MB991895) which is used during installation of transmission assembly to hold the engine assembly (Refer to GROUP 22A - Transmission Assembly ).
4.Remove the garage jack which supports the engine assembly.

>>C<< A/C COMPRESSOR ASSEMBLY INSTALLATION

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