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

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

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

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 ).

Transmission Fluid Draining (Refer to GROUP 23A, On-vehicle Service - Automatic Transmission Fluid Change ).

Transfer Oil Draining (Refer to GROUP 23A, On-vehicle Service - Transfer Oil Replacement ).

Hood Removal (Refer to GROUP 42, Hood ).

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

Battery and Battery Tray Removal

Accelerator Cable Removal (Refer to GROUP 17, Accelerator Cable and Pedal ) <L.H. drive vehicles>.

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

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

Post-installation Operation

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

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

Accelerator Cable Installation (Refer to GROUP 17, Accelerator Cable and Pedal ) <L.H. drive vehicles>.

Battery and Battery Tray Installation

Air Cleaner Installation (Refer to GROUP 15, Air Cleaner ).

Hood Installation (Refer to GROUP 42, Hood ).

Transfer Oil Refilling (Refer to GROUP 23A, On-vehicle Service - Transfer Oil Replacement ).

Transmission Fluid Refilling (Refer to GROUP 23A, On-vehicle Service - Automatic Transmission Fluid Change ).

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 ) <L.H. drive vehicles>.

Fuel Leak Check

Drive Belt Tension Check (Refer to ).

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

Front Wheel Alignment Check and Adjustment (Refer to GROUP 33, On-vehicle Service - Front Wheel Alignment Check and Adjustment ).

		Removal steps
	1.	Control wiring harness connection
	2.	Battery wiring harness connection
	3.	Canister vacuum hose connection
	4.	Brake booster vacuum hose connection
<<A>>	5.	Drive belt

			Removal steps
<<B>>		6.	Power steering oil pump and bracket assembly
<<C>>		7.	A/C compressor and clutch assembly
		8.	Heater water hoses connection
<<D>>	>>E<<	9.	Fuel high-pressure hose connection
<<E>>	>>D<<	•	Transmission assembly
		10.	Earth cable connection
	>>C<<	11.	Self-locking nuts
<<F>>	>>B<<	12.	Engine mounting insulator
<<G>>	>>A<<	13.	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>> POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL

With the hose installed, remove the power steering oil pump and bracket assembly from the engine assembly.

NOTE: After removing the power steering oil pump and bracket assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<C>> A/C COMPRESSOR AND CLUTCH ASSEMBLY REMOVAL

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

NOTE: After removing the A/C compressor and clutch assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<D>> FUEL HIGH-PRESSURE HOSE REMOVAL

Remove the fuel high-pressure hose stopper.

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.

<<E>> TRANSMISSION ASSEMBLY REMOVAL

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

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

<<F>> 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 bolts, and remove the engine mounting insulator.

<<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 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<< SELF-LOCKING NUTS INSTALLATION

CAUTION

Do not tighten the self-locking nuts while the engine is hot.

Tighten the self-locking nuts to the specified torque while the engine is cold.

Tightening torque: 45 ± 5 N·m

>>D<< TRANSMISSION ASSEMBLY INSTALLATION

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

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

>>E<< FUEL HIGH-PRESSURE HOSE INSTALLATION

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.