Removal and Replacement
ENGINE ASSEMBLYREMOVAL AND INSTALLATION
CAUTION:
When the engine assembly replacement is performed, use scan tool MB991958 to initialize the learning value.
Pre-removal & Post-installation Operation:
Removal Steps 1-9:
Removal Steps 10-14:
Required Special Tools:
^ MB991454: Engine Hanger Balancer
^ MB991895: Engine Hanger
^ MB991928: Engine Hanger
^ MB992201: Engine Hanger Plate
REMOVAL SERVICE POINTS
[A] RADIATOR UPPER HOSE/RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp as shown to install them in the original position. Then, remove them.
[B] FUEL HIGH-PRESSURE HOSE DISCONNECTION
1. Remove the stopper of the fuel high-pressure hose.
2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.
NOTE: If the retainer is released, install it securely after removing the fuel high-pressure hose.
[C] POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1. Remove the power steering oil pump assembly together with the hose from the bracket.
2. Tie the removed power steering oil pump assembly with a string at a position where it will not interfere with the removal and installation of engine assembly.
[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 it will not interfere with the removal and installation of engine assembly.
[E] MANUAL TRANSAXLE ASSEMBLY/CVT ASSEMBLY REMOVAL
1. Install the front end upper bar bolts to the position as shown in the figure.
2. Remove the transaxle assembly.
[F] ENGINE MOUNTING INSULATOR REMOVAL
CAUTION:
When supporting the engine assembly with a garage jack, be careful not to deform the engine oil pan.
1. 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 MB991928 or MB991895 and MB992201 which was installed for supporting the engine assembly when the transaxle assembly was removed.
3. Operate a garage jack so that the engine weight is not applied to the engine mounting insulator, and remove the engine mounting insulator.
[G] ENGINE ASSEMBLY REMOVAL
1. Mount the special tool MB991454 to the power steering oil pump bracket and the engine hanger, and set the chain block.
2. After checking that all cables, hoses and wiring harness connectors and so on are disconnected from the engine, lift the engine assembly slowly with the chain block 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
CAUTION:
When supporting the engine assembly with a garage jack, be careful not to deform the engine oil pan.
1. 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 assembly.
2. Remove special tool MB991454.
3. Install special tool MB992201 and MB991928 or MB991895 which is used during installation of transaxle assembly to hold the engine assembly.
[C] 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 Nm (17 ± 4 ft-lb)
[D] FUEL HIGH-PRESSURE HOSE CONNECTION
CAUTION:
After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 3 mm (0.12 inch) play. After the check, install the stopper securely.
Apply a small amount of engine oil to the fuel line pipe, and install the fuel high-pressure hose.
[E] RADIATOR LOWER HOSE/RADIATOR UPPER HOSE CONNECTION
1. Insert radiator hose as far as the projection of the water inlet fitting or water outlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.