REMOVAL AND INSTALLATION


Pre-removal Operation
  • Hood Removal (Refer to GROUP 42A - Hood ).
  • Fuel Line Pressure Reduction (Refer to GROUP 13D - 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 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Intercooler Intake Air Hose A, Intercooler Outlet Air Hose D and Intercooler Intake Air Pipe A, B Removal (Refer to GROUP 15 - Intercooler ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Catalytic Converter Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).

 Post-installation Operation
  • Catalytic Converter Installation (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic Converter ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Intercooler Intake Air Hose A, Intercooler Outlet Air Hose D and Intercooler Intake Air Pipe A, B Installation (Refer to GROUP 15 - Intercooler ).
  • 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 ).
  • Fuel Leak Check
  • Drive Belt Tension Check (Refer to ).
  • 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
<<A>>
·
 Cowl top panel (Refer to GROUP 42A - Loose Panel )


1.
 Front wiring harness and control wiring harness combination


2.
 Front wiring harness and control wiring harness combination


3.
 Earthing connection


4.
 Battery wiring harness connection


5.
 Vacuum hose connection


6.
 Heater hose connection


·
 Water by-pass hose connection (Refer to GROUP 14 - Radiator )
<<B>>
 >>D<<
 7.
 Radiator upper hose connection
<<C>>
 >>C<<
 8.
 Hose clip
<<C>>
 >>C<<
 9.
 Radiator lower hose connection


10.
 Fuel main hose connection


11.
 Fuel return hose connection


·
 Drive belt (Refer to )
<<D>>
 >>B<<
 12.
 A/C compressor and clutch assembly


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


·
 Radiator condenser tank (Refer to GROUP 14 - Radiator )
<<E>>
 >>A<<
 13.
 Engine mounting bracket
<<E>>
 >>A<<
 14.
 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>> RADIATOR UPPER HOSE DISCONNECTION

Make mating marks on the radiator hose and the hose clamp. Disconnect the radiator hose.

<<C>> HOSE CLIP/RADIATOR LOWER HOSE DISCONNECTION

1.Make mating marks on the radiator lower 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.

<<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>> ENGINE MOUNTING BRACKET/ENGINE ASSEMBLY 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 tool 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 ) <M/T> or (Refer to GROUP 23A - Transmission Assembly ) A/T>.

3.Install the engine hanger right (MD016967) to the cylinder block.

4.Hold the engine assembly with a chain block.
5.Place a garage jack against the engine oil pan with a piece of wood in between, and remove the engine mounting bracket while adjusting the position of the engine.
6.After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, raise the vehicle slowly with a lift, and remove the engine assembly upwards from the engine compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY/ENGINE MOUNTING BRACKET INSTALLATION
1.Place the engine assembly below the lifted vehicle.
2.Install the engine assembly, being careful not to pinch the cables, hoses, or wiring harness connectors.

3.Install the engine hanger right (MD016967) to the cylinder block.

4.Set special tool engine hanger balancer (MB991454) and a chain block to the engine assembly.
5.
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.
6.Remove the chain block.


7.Install special tool 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 ) A/T>.
8.Remove the garage jack.

>>B<< 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

>>C<< RADIATOR LOWER 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 lower hose until the protrusion of the inlet fitting water pipe.
3.Align the mating marks on the radiator lower hose and hose clip.
4.Remove the hose clip claw and shorten the hose clip, then install the radiator lower hose.

>>D<< RADIATOR UPPER HOSE CONNECTION

1.Insert radiator hose as far as the projection of the cooling water outlet fitting.
2.Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.