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 ) <LH drive vehicles>.
  • Hood Removal (Refer to GROUP 42A - Hood ) <RH drive vehicles>.
  • Fuel Line Pressure Reduction (Refer to GROUP 13A - On-vehicle Service, How to Reduce Pressurized Fuel Lines ).
  • Engine Room Under Cover Front A, B, D and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Transmission Fluid Draining (Refer to GROUP 23A - On-vehicle Service, CVT Fluid Replacement ).
  • Transfer Oil Draining (Refer to GROUP 23A - On-vehicle Service, Transfer Oil Replacement ).
  • 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 13A - Engine-ECU ).
  • Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold ).
  • Alternator and Others Belt Removal (Refer to ).

Post-installation Operation
  • Alternator and Others Belt Installation (Refer to ).
  • Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold ).
  • Engine-ECU Installation (Refer to GROUP 13A - 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 ).
  • Transfer Oil Refilling (Refer to GROUP 23A - On-vehicle Service, Transfer Oil Replacement ).
  • Transmission Fluid Refilling (Refer to GROUP 23A - On-vehicle Service, CVT Fluid Replacement ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14A - On-vehicle Service, Engine Coolant Replacement ).
  • Alternator and Others Belt Tension Check (Refer to ).
  • Engine Room Under Cover Front A, B, D and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).
  • Fuel Leak Check.
  • Hood Installation (Refer to GROUP 42A - Hood ) <LH drive vehicles>.
  • Hood Installation (Refer to GROUP 42A - Hood ) <RH drive vehicles>.





Removal steps


1.
Control wiring harness connection


2.
Battery cable connection
<<A>>
>>F<<
3.
Hose clip
<<A>>
>>F<<
4.
Radiator upper hose connection
<<A>>
>>F<<
5.
Hose clip
<<A>>
>>F<<
6.
Radiator lower hose connection


7.
Heater hose connection


8.
Canister vacuum hose connection


9.
Brake booster vacuum hose connection
<<B>>
>>E<<
10.
Fuel high-pressure hose connection


·
Alternator and others belt (Refer to )




Removal steps
<<C>>
>>D<<
11.
A/C compressor and clutch assembly


12.
Inlet manifold assembly (Refer to GROUP 15 - Inlet Manifold )


·
Transmission assembly (Refer to GROUP 23A - Transmission Assembly ).

>>C<<
13.
Earth cable connection
<<D>>
>>B<<
14.
Engine mounting bracket
<<E>>
>>A<<
15.
Engine assembly

REMOVAL SERVICE POINTS



<<A>> HOSE CLIP/RADIATOR HOSE DISCONNECTION



1.Make mating marks on the radiator hose and the hose clip as shown to install them in the original position.

2.Break off the tip of hose clip claw and spread out the hose clip, then disconnect the radiator lower hose.
note If there is a hose clip claw, the hose clip cannot spread to capacity because the claw contacts the hose clip.

<<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>> 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 it will not interfere with the removal and installation of engine assembly.

<<D>> ENGINE MOUNTING BRACKET 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 (MB992853) which was installed for supporting the engine assembly when the transmission assembly was removed (Refer to GROUP 23A - Transmission Assembly ).
3.Operate a garage jack so that the engine weight is not applied to the engine mounting bracket, and remove the engine mounting bracket.

<<E>> ENGINE ASSEMBLY REMOVAL



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




1. Install special tool engine hanger plate (MB991956) to the cylinder head, and set special tool hanger (MB991527) and the chains of special tool engine hanger balancer (MB991454) to the engine assembly to hold the engine assembly.
2.Install the engine assembly, being careful not to pinch the cables, hoses, or wiring harness connectors.

>>B<< ENGINE MOUNTING BRACKET 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 bracket while adjusting the position of the engine.


2.Install special tool engine hanger (MB991928 or MB991895) which is used during installation of transmission assembly to hold the engine assembly (Refer to GROUP 23A - Transmission Assembly ).
3.Remove the garage jack which supports the engine assembly.

>>C<< EARTH CABLE CONNECTION



1.Install the earth cable in the direction shown in the illustration.
2.Tighten the alternator mounting bolt to the specified torque.
Tightening torque: 44 ± 10 N·m

>>D<< 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

>>E<< 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.

>>F<< RADIATOR HOSE/HOSE CLIP CONNECTION


1.
caution Never reuse the hose clip whose claw is broken off to prevent the rusting.
Make mating mark on a new hose clip in the same position as the remove one.

2.Insert the radiator hose until the protrusion of the pipe.
3.Align the mating marks on the radiator hose and hose clip.
4.Remove the hose clip claw and shorten the hose clip, then install the radiator hose.