Removal and Replacement

ENGINE ASSEMBLY

REMOVAL AND INSTALLATION

CAUTION:
^ When the engine assembly replacement is performed, use scan tool MB991958 to initialize the learning value.
^ If the vehicle is equipped with the Brembo(TM) disc brake, during maintenance, take care not to contact the parts or tools to the caliper because the paint of caliper will be scratched.
^ *: Indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body.

Pre-removal & Post-installation Operation:

Removal Steps 1-13:

Removal Steps 14-22:

Removal Steps 23-40:

Removal Steps 23-40 & Required Special Tools:

REMOVAL SERVICE POINTS
[[A]] DRIVE BELT REMOVAL
The following operations will be needed due to the serpentine drive system with the drive belt auto-tensioner.





1. Securely insert the spindle handle or ratchet handle with a 12.7 mm (1/2-inch) insertion angle into the jig hole of the auto-tensioner, and turn the auto-tensioner counterclockwise until it hits the stopper.

CAUTION: To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.





2. Align hole A with hole B, insert an L-shaped hexagon wrench, etc. to fix and then remove the drive belt.

[[B]] POWER STEERING OIL PUMP, BRACKET AND RESERVOIR ASSEMBLY/ A/C COMPRESSOR AND CLUTCH ASSEMBLY [VEHICLE WITH A/C> REMOVAL
With the hose installed, remove the power steering oil pump assembly, and A/C compressor and clutch assembly from the bracket.

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

[[C]] TRANSAXLE ASSEMBLY REMOVAL





1. Pre-tighten the 2 bolts on the car to assemble the radiator support upper insulator to set the special tools MZ203827, MB991895 or MB991928.
2. Remove the transaxle assembly.

[[D]] SELF-LOCKING NUTS/ENGINE MOUNTING INSULATOR AND CUSHION STOPPERS ASSEMBLY REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.





1. [Engine lifter (special tool MZ203827) is used] Remove special tool MZ203827.





2. [Engine hanger (special tool MB991895) is used] Remove special tool MB991895.





3. [Engine hanger (special tool MB991928) is used] Remove the base hanger and the following tool.
^ Slide bracket (HI)
^ Foot (standard) (MB991932)
^ Joint (90) (MB991930)





3. Hold the engine assembly with a chain block, etc.
4. 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 front mounting bracket.
5. Loosen the engine mounting insulator mounting nuts and bolt. Remove the engine mounting insulator and cushion stopper assembly.

[[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 AND CUSHION STOPPERS ASSEMBLY/SELF-LOCKING NUTS INSTALLATION





1. Arrow marks on the engine mounting cushion stopper should face the shown direction.

NOTE: Disregard F and R stamped as a shared part.

2. Place a garage jack against the engine oil pan with a piece of wood in between. Install the engine mounting insulator and cushion stoppers while adjusting the position of the engine.
3. Support the engine assembly with a garage jack.
4. Remove the chain block.
5. Use the following special tool as during removal to support the engine.





1. [Engine lifter (special tool MZ203827) is used] Set special tool MZ203827.





2. [Engine hanger (special tool MB991895) is used] Set special tool MB991895.
3. [Engine hanger (special tool MB991928) is used]





a. Set the following parts to the base hanger.
^ Slide bracket (HI)
^ Foot (standard) (MB991932)
^ Joint (90) (MB991930)





b. Set special tool MB991928.

]]C[[ TRANSAXLE ASSEMBLY INSTALLATION
1. Install the transaxle assembly.





2. 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 fuel rail.

1. Apply a small amount of new engine oil to the O-ring.
2. Turning the fuel high-pressure hose to the right and left, install it to the fuel rail, being careful not to damage the O-ring. After installing, check that the hose turns smoothly.
3. 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 fuel rail and check that the hose turns smoothly.
4. Tighten the fuel high-pressure hose mounting bolts to the specified torque.
Tightening torque: 5.0 ± 1.0 Nm (44 ± 9 inch lbs.)