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

Fuel Line Pressure Reduction [Refer to GROUP 13A, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].

Hood Removal (Refer to GROUP 42, Hood ).

Under 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 ).

Intercooler Removal (Refer to GROUP 15, Intercooler ).

Air Cleaner and Air Cleaner Bracket Removal (Refer to GROUP 15, Air Cleaner ).

Battery and Battery Tray Removal

Radiator Assembly Removal (Refer to GROUP 14, Radiator ).

Front Axle Crossmember Bar Removal (Refer to GROUP 32, Engine Roll Stopper and Centermember ).

Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).

Starter Assembly Removal (Refer to GROUP 16, Starter Motor Assembly ).

Post-installation Operation

Starter Assembly Installation (Refer to GROUP 16, Starter Motor Assembly ).

Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).

Front Axle Crossmember Bar Installation (Refer to GROUP 32, Engine Roll Stopper and Centermember ).

Radiator Assembly Installation (Refer to GROUP 14, Radiator ).

Battery and Battery Tray Installation

Air Cleaner and Air Cleaner Bracket installation (Refer to GROUP 15, Air Cleaner ).

Intercooler Installation (Refer to GROUP 15, Intercooler ).

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 ).

Accelerator Cable Adjustment (Refer to GROUP 17, On-vehicle Service - Accelerator Cable Check and Adjustment ).

Drive Belt Tension Check (Refer to ).

Under Cover Installation (Refer to GROUP 51, Under Cover ).

Hood Installation (Refer to GROUP 42, Hood ).

Fuel Leak Check

		Removal steps
	1.	A/C compressor connector
	2.	Power steering oil pressure switch connector
	3.	Crank angle sensor connector
	4.	Ignition coil connectors
	5.	Manifold differential pressure sensor connector
	6.	Detonation sensor connector
	7.	Purge control solenoid valve connector
	8.	EGR control solenoid valve connector
	9.	Injector connectors
	10.	Throttle position sensor connector
	11.	Idle speed control servo connector
	12.	Camshaft position sensor connector
	13.	Capacitor connector
	14.	Engine coolant temperature sensor connector
	15.	Engine coolant temperature gauge unit connector
	16.	Wastegate solenoid valve connector
	17.	Fuel pressure control solenoid valve connector
	18.	Battery wiring harness connection
	19.	Accelerator cable connection
<<A>>	20.	Drive belt

			Removal steps
		21.	Brake booster vacuum hose connection
		22.	Canister vacuum hose connection
<<B>>		23.	A/C compressor and clutch assembly
<<B>>		24.	Power steering oil pump assembly
		25.	Heater water hoses connection
		26.	Fuel return line hose connection
	>>D<<	27.	Fuel high-pressure hose connection
	>>D<<	28.	O-ring
<<C>>	>>C<<	•	Transmission assembly
		29.	Self-locking nuts
<<D>>	>>B<<	30.	Engine mounting insulator
<<E>>	>>A<<	31.	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.

Securely insert the spindle handle or ratchet handle with a 12.7 mm insertion angle into the jig hole of the auto-tensioner.

Rotate the auto-tensioner anti-clockwise and align hole A with hole B.

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>> A/C COMPRESSOR AND CLUTCH ASSEMBLY/POWER STEERING OIL PUMP ASSEMBLY REMOVAL

With the hose installed, remove the A/C compressor and clutch assembly, and power steering oil pump assembly from the bracket.

NOTE: Secure the removed A/C compressor and clutch assembly, and power steering oil pump assembly with cord or rope at a position where they will not interfere with the removal of the engine assembly.

<<C>> TRANSMISSION ASSEMBLY REMOVAL

Pre-tighten the 2 bolts on the car to assemble the radiator support upper insulator to set the special tools engine hanger MB991895 or engine hanger MB991928.

Remove the transmission assembly (Refer to GROUP 23A, Transmission Assembly ).

<<D>> ENGINE MOUNTING INSULATOR REMOVAL

Support the engine with a garage jack.

Remove the following special tool.

<Special tool engine hanger (MB991895) is used>

Remove special tool MB991895.

<Special tool engine hanger (MB991928) is used>

Remove special tool MB991928.

Hold the engine assembly with a chain block, etc.

Place a garage jack against the engine oil pan with a piece of wood in between so that the weight of the engine assembly is no longer being applied to the engine mounting insulator.

Loosen the engine mounting insulator mounting nuts and bolt, 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 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 INSULATOR INSTALLATION

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.

Support the engine assembly with a garage jack.

Remove the chain block.

Use the following special tool as during removal to support the engine.

<Special tool engine hanger (MB991895) is used>

Set special tool MB991895. (Refer to GROUP 23A, Transmission Assembly ).

<Special tool engine hanger (MB991928) is used>

Set special tool MB991928 (Refer to GROUP 23A, Transmission Assembly ).

>>C<< TRANSMISSION ASSEMBLY INSTALLATION

Install the transmission assembly (Refer to GROUP 23A, Transmission Assembly ).

Remove from the car the 2 bolts, to assemble the radiator support upper insulator.

>>D<< O-RING/FUEL HIGH-PRESSURE HOSE INSTALLATION

CAUTION

Do not let any engine oil get into the delivery pipe.

Apply a small amount of new engine oil to the O-ring.

Turning the fuel high-pressure hose to the right and left, install it to the delivery pipe, while being careful not to damage the O-ring. After installing, check that the hose turns smoothly.

If the hose does not turn smoothly, the O-ring is probably being clamped. Disconnect the fuel high-pressure hose and check the O-ring for damage. After this, re-insert it to the delivery pipe and check that the hose turns smoothly.

Tighten the fuel high-pressure hose mounting bolts to the specified torque.

Tightening torque: 5.0 ± 1.0 N·m