REMOVAL AND INSTALLATION


caution
  • When the engine assembly replacement is performed, use M.U.T.-III to initialise the learning value (Refer to GROUP 00 - Initialisation Procedure for Learning Value in MPI Engine ).
  • *: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body.
Pre-removal Operation
  • Hood Removal (Refer to GROUP 42A - Hood ).
  • Fuel Line Pressure Reduction [Refer to GROUP 13C - On-vehicle Service, Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].
  • Engine Room Under Cover Front B and Engine Room Side Cover (RH) Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement <4B1, 6B3> ).
  • Engine Oil Draining <4B1, 6B3> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Transmission Fluid Draining (Refer to GROUP 23C - On-vehicle Service, A/T Fluid Replacement ).
  • Transfer Oil Draining (Refer to GROUP 23C - On-vehicle Service, Transfer Oil Replacement ).
  • Engine Cover Removal (Refer to GROUP 16 - Ignition System, Ignition Coil <6B3> ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner <6B3> ).
  • Engine-ECU Removal (Refer to GROUP 13C - Engine-ECU ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Front Exhaust Pipe and Front Exhaust Pipe RH Removal (Refer to GROUP 15 - Exhaust Pipe and Main Muffler <6B3> ).
  • Strut Tower Bar Removal (Refer to GROUP 42A - Strut Tower Bar ).
  • Drive shaft Removal (Refer to GROUP 26 - Drive Shaft Assembly ).
  • Propeller Shaft Removal (Refer to GROUP 25 - Propeller Shaft ).
  • Pressure Hose Assembly and Return Tube B Removal (Refer to GROUP 37 - Power Steering Hoses ).
  • Rear Roll Stopper Removal (Refer to GROUP 32 - Engine Roll Stopper and Centremember ).
  • Transfer Removal (Refer to GROUP 23C - Transfer Assembly ).
  • Starter Removal (Refer to GROUP 16 - Starting System, Starter Assembly <6B3> ).
  • Radiator Upper Hose and Radiator Lower Hose Removal (Refer to GROUP 14 - Radiator <6B3> ).

 Post-installation Operation
  • Radiator Upper Hose and Radiator Lower Hose Installation (Refer to GROUP 14 - Radiator <6B3> ).
  • Starter Installation (Refer to GROUP 16 - Starting System, Starter Assembly <6B3> ).
  • Transfer Installation (Refer to GROUP 23C - Transfer Assembly ).
  • Rear Roll Stopper Installation (Refer to GROUP 32 - Engine Roll Stopper and Centremember ).
  • Pressure Hose Assembly and Return Tube B Installation (Refer to GROUP 37 - Power Steering Hoses ).
  • Propeller Shaft Installation (Refer to GROUP 25 - Propeller Shaft ).
  • Drive shaft Installation (Refer to GROUP 26 - Drive shaft Assembly ).
  • Strut Tower Bar Installation (Refer to GROUP 42A - Strut Tower Bar ).
  • Front Exhaust Pipe and Front Exhaust Pipe RH Installation (Refer to GROUP 15 - Exhaust Pipe and Main Muffler <6B3> ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Engine-ECU Installation (Refer to GROUP 13C - Engine-ECU ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner <6B3> ).
  • Alternator Drive Belt Tension Check (Refer to ).
  • Power Steering Oil Pump Drive Belt Tension Check and Adjustment (Refer to ).
  • Engine Oil Refilling <4B1, 6B3> (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Transmission Fluid Refilling (Refer to GROUP 23C - On-vehicle Service, A/T Fluid Replacement ).
  • Transfer Oil Refilling (Refer to GROUP 23C - On-vehicle Service, Transfer Oil Replacement ).
  • Engine Coolant Refilling <4B1, 6B3> (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Fuel Leak Check.
  • Engine Cover Installation (Refer to GROUP 16 - Ignition System, Ignition Coil <6B3> ).
  • Engine Room Under Cover Front B and Engine Room Side Cover (RH) Installation (Refer to GROUP 51 - Under Cover ).
  • Hood Installation (Refer to GROUP 42A - Hood ).




Removal steps
<<A>>
1.
 Alternator drive belt


2.
 Power steering tensioner pulley bracket assembly
<<B>>
3.
 Power steering oil pump drive belt


4.
 Earth cable connection
<<C>>
 >>B<<
 5.
 Fuel high-pressure hose connection


6.
 Heater hose connection


·
 Air intake plenum (Refer to GROUP 15 - Air Intake Plenum <6B3 (Vehicles without EGR)> ).


·
 Air intake plenum (Refer to GROUP 15 - Air Intake Plenum <6B3 (Vehicles with EGR)> ).


·
 Right bank exhaust manifold (Refer to GROUP 15 - Exhaust Manifold <6B3> ).




Removal steps


7.
 Engine hanger


·
 Transmission assembly (Refer to GROUP 23C - Transmission Assembly ).
<<D>>
8.
 Power steering oil pump assembly
<<E>>
9.
 A/C compressor and clutch assembly


10.
 Control wiring harness (relay box side)


11.
 Control wiring harness (battery side)
<<F>>
 >>A<<
 12.
 Engine mounting bracket

>>A<<
 13.
 Engine mounting insulator stopper
<<G>>
 >>A<<
 14.
 Engine assembly


15.
 Control wiring harness

REMOVAL SERVICE POINTS

<<A>> ALTERNATOR DRIVE BELT REMOVAL
To introduce the serpentine drive system with the alternator drive belt auto-tensioner, the following operations will be required.

1.
caution To reuse the alternator drive belt, draw an arrow indicating the rotating direction on the back of the alternator drive belt using chalk to install the same direction.
Turn the alternator drive belt auto-tensioner to anti-clockwise, and insert the L-shaped hexagon wrench to the alternator drive belt auto-tensioner hole in order to fix the auto-tensioner.
2.Remove the alternator drive belt.

<<B>> POWER STEERING OIL PUMP DRIVE BELT REMOVAL
caution To reuse the power steering oil pump drive belt, draw an arrow indicating the rotating direction on the back of the power steering oil pump drive belt using chalk to install the same direction.

<<C>> FUEL HIGH-PRESSURE HOSE DISCONNECTION

1.Remove the fuel high-pressure hose stopper.

2.Remove the fuel high-pressure hose in the direction shown in the figure while the retainer is pulled up.
note If the retainer is released, install it after removing the fuel high-pressure hose.

<<D>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1.Remove the power steering oil pump assembly from the engine with the hose attached.
2.Place the removed power steering oil pump assembly in a place where it will not be a hindrance when removing and installing the engine assembly, and secure it with a cord or wire.

<<E>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL
1.Remove the A/C compressor and clutch assembly from the A/C compressor bracket with the hose still attached.
2.Place the removed A/C compressor and clutch assembly where it will not be a hindrance when removing and installing the engine assembly, and secure it with a cord or wire.

<<F>> 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 the special tool engine hanger (MB991895 or MB991928) for supporting the engine which were installed when removing the transmission assembly.

3.The installation position at the right bank side of special tool engine hanger balancer (MB991454) for supporting the engine installed when removing the transmission assembly has been changed from special tool engine hanger plate A (MB992208) (Right bank) to engine right hanger, and support the engine assembly using the chain block or others.
4.Loosen the engine mounting bracket mounting nuts and bolt, and remove the engine mounting bracket.

<<G>> 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 upward from the engine compartment.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY/ENGINE MOUNTING INSULATOR STOPPER/ENGINE MOUNTING BRACKET INSTALLATION

1.Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.

2.Mount the engine mounting insulator stopper to be positioned as shown in the figure, then mount the engine mounting bracket.
3.
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.


4.Remove the chain block or others and install the special tool engine hanger (MB991895 or MB991928) (Refer to GROUP 23C - Transmission Assembly ).
At this time, contrary to the removal, the installation position at the right bank side of special tool engine hanger balancer (MB991454) for supporting the engine has been changed from engine right hanger to special tool engine hanger plate A (MB992208) (Right bank).

>>B<< FUEL HIGH-PRESSURE HOSE CONNECTION
caution After connecting the fuel high-pressure hose, slightly pull it to ensure that it is installed securely. Also confirm that there is a play approximately 3 mm. Then install the stopper securely.


Apply a small amount of engine oil to the fuel line pipe and then install the fuel high-pressure hose.