REMOVAL AND INSTALLATION


caution *: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body.
Pre-removal Operation
  • Engine Room Under Cover and Side Cover 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 ).
  • Transmission Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ).
  • Transfer Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transfer Oil Replacement ).
  • Catalytic Converter Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • Drive Shaft Removal (Refer to GROUP 26 - Drive Shaft Assembly .)
  • Hood Removal (Refer to GROUP 42 - Hood ).
  • Strut Tower Bar Removal (Refer to GROUP 42 - Strut Tower Bar ).
  • Battery and Battery Tray Removal.
  • Air Cleaner Removal (Refer to GROUP 15 - Air Cleaner ).
  • Intercooler Air Hose D, E and Air Pipe A, D Removal (Refer to GROUP 15 - Intercooler ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).

 Post-installation Operation
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Intercooler Air Hose D, E and Air Pipe A, D Installation (Refer to GROUP 15 - Intercooler ).
  • Air Cleaner Installation (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Installation
  • Strut Tower Bar Installation (Refer to GROUP 42 - Strut Tower Bar ).
  • Hood Installation (Refer to GROUP 42 - Hood ).
  • Drive Shaft Installation (Refer to GROUP 26 - Drive Shaft Assembly .)
  • Catalytic Converter Installation (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • Transfer Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transfer Oil Replacement ).
  • Transmission Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ).
  • 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 ).
  • Fuel Leak Check
  • Engine Room Under Cover and Side Cover Installation (Refer to GROUP 51 - Under Cover ).




Removal steps


1.
 Engine cover


2.
 Insulator


3.
 Glow and injector intermediate connector


4.
 Engine coolant temperature sensor connector


5.
 Fuel temperature sensor connector


6.
 Control wiring harness and engine wiring harness combination connector


7.
 Control wiring harness connection


8.
 Alternator connector


9.
 A/C compressor connector


10.
 Battery wiring harness connection


11.
 Brake booster vacuum hose connection
<<A>>
12.
 Drive belt


13.
 Vacuum hose and pipe assembly




Removal steps
<<B>>
14.
 Power steering oil pump


15.
 Cap


16.
 Idler pulley


17.
 Dust cover


18.
 Alternator
<<C>>
19.
 A/C compressor


20.
 Heater water hoses connection


21.
 Fuel return line hose connection


22.
 Fuel line hose connection


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


·
 Transmission assembly (Refer to GROUP 22A - Transmission Assembly )
<<D>>
 >>B<
 23.
 Engine mounting insulator
<<E>>
 >>A<<
 24.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> 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.
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 and then remove the drive belt.

<<B>> 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.

<<C>> A/C COMPRESSOR REMOVAL
1.With the hose installed, remove the A/C compressor from the bracket.
2.After removing the A/C compressor, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<D>> ENGINE MOUNTING INSULATOR REMOVAL
1.Place a garage jack against the engine oil pan with a piece of wood in between to support the engine assembly.


2.When the transmission assembly is removed, remove the special tool which supports the engine assembly.
(1) <When engine hanger (Special tool: MB991928) is used>
.....1. Remove the special tool (MB991928).
(2) <When engine hanger (Special tool: MB991895) is used>
.....1. Remove the special tool (MB991895).
3.Operate a garage jack so that the engine weight is not applied to the engine mounting insulator, and remove the engine mounting insulator.

<<E>> ENGINE ASSEMBLY REMOVAL
After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the chain block slowly to remove the engine assembly downwards 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.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.


2.Install a special tool which is used during installation of transmission assembly to hold the engine assembly. (Refer to GROUP 22A - Transmission Assembly .)
(1) <When engine hanger (Special tool: MB991928) is used>
(2) <When engine hanger (Special tool: MB991895) is used>