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 13C - On-vehicle Service, 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 14A - 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 Replacement ) <M/T>.
  • Transmission Fluid Draining (Refer to GROUP 23A - On-vehicle Service, CVT Fluid Replacement ) <CVT>.
  • Engine Upper Cover Removal (Refer to ).
  • Air Cleaner Assembly and Air Cleaner Bracket Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Exhaust Manifold Removal (Refer to GROUP 15 - Exhaust Manifold ).
  • Drive Belt Removal (Refer to ).

Post-installation Operation
  • Drive Belt Installation (Refer to ).
  • Exhaust Manifold Installation (Refer to GROUP 15 - Exhaust Manifold ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly and Air Cleaner Bracket Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Upper Cover Installation (Refer to ).
  • Transmission Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ) <M/T>.
  • Transmission Fluid Refilling (Refer to GROUP 23A - On-vehicle Service, CVT Fluid Replacement ) <CVT>.
  • 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 ).
  • 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 ).
  • Hood Installation (Refer to GROUP 42A - Hood ).





Removal steps


1.
Battery wiring harness connection


2.
Control wiring harness connection


3.
Earth cable connection


·
Heater hose connection (Refer to GROUP 14A - Water Hose and Water Pipe ).


·
Radiator upper hose connection (Refer to GROUP 14A - Water Hose and Water Pipe ).


·
Radiator lower hose connection (Refer to GROUP 14A - Thermostat ).


·
Water hose connection (Refer to GROUP 12 - Engine Oil Cooler ) <CVT>.
<<A>>

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


·
Fuel high-pressure hose (Refer to GROUP 13C - Injector ).


·
Transmission assembly (Refer to GROUP 22A - Transmission Assembly ) <M/T>.


·
Transmission assembly (Refer to GROUP 23A - Transmission Assembly ) <CVT>.
<<B>>
>>B<<
·
Engine mounting bracket (Refer to GROUP32 - Engine mounting ).
<<C>>
>>A<<
4.
Engine assembly

REMOVAL SERVICE POINTS



<<A>> 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.

<<B>> ENGINE MOUNTING BRACKET 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 the special tool for holding the engine assembly, which has been set when the transmission assembly is removed.

  • Engine hanger (MB991928 or MB991895)
  • Hanger (MB991527)
  • Chain of engine hanger balancer (MB991454)
  • Engine hanger plate (MB992853)
3.Remove the motor bracket (Refer to ).

4.Install special tool engine hanger plate (MB991956) to the motor bracket mounting of the cylinder head.

5.Set the following special tools to special tool MB991956 and the engine hanger to hold the engine assembly.

  • Hanger (MB991527)
  • Chain of engine hanger balancer (MB991454)
6.Operate a garage jack so that the engine weight is not applied to the engine mounting insulator, and remove the engine mounting bracket.

<<C>> 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


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 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.Remove the special tool for holding the engine assembly.

  • Hanger (MB991527)
  • Chain of engine hanger balancer (MB991454)
  • Engine hanger plate (MB991956)
3.Install the motor bracket (Refer to ).



4.Secure the special tool for holding the engine assembly, which will be used when the transmission assembly is installed (Refer to GROUP 22A -Transmission Assembly ) <M/T> or (Refer to GROUP 23A -Transmission Assembly ) <CVT>.

  • Engine hanger (MB991928 or MB991895)
  • Hanger (MB991527)
  • Chain of engine hanger balancer (MB991454)
  • Engine hanger plate (MB992853)
5.Remove the garage jack which supports the engine assembly.