Removal and Replacement
ENGINE ASSEMBLYREMOVAL AND INSTALLATION
CAUTION:
^ When the engine assembly replacement is performed, use scan tool MB991958 to initialize the learning value.
^ 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 1-4:
Removal Steps 5-13:
Required Special Tools:
^ MB991454: Engine Hanger Balancer
^ MB991527: Hanger
^ MB991895: Engine Hanger
^ MB991928: Engine Hanger
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.
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.
2. Rotate the auto-tensioner counterclockwise 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.
3. 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
1. With the hose installed, remove the power steering oil pump and bracket assembly from the engine assembly.
2. 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
1. With the hose installed, remove the A/C compressor and clutch assembly from the bracket.
2. 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]] ATF WARMER (TRANSMISSION FLUID COOLER) AND BRACKET ASSEMBLY REMOVAL
With the hose installed, remove the ATF warmer (transmission fluid cooler) and bracket assembly from the transmission case front roll stopper bracket.
[[E]] 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.
[[F]] TRANSAXLE ASSEMBLY REMOVAL
1. Frame front end structure bar provisorily.
NOTE: Secure A/C condenser and front end structure bar with a cord in the location where the removal and installation of the engine assembly cannot be hindered.
2. Remove the transaxle assembly.
[[G]] POWER STEERING OIL RESERVOIR REMOVAL
1. With the hose installed, remove the power steering oil reservoir from the vehicle.
2. After removing the power steering oil reservoir, secure it with a cord in the location where the removal and installation of the engine front mounting bracket cannot be hindered.
[[H]] ENGINE FRONT MOUNTING BRACKET REMOVAL
1. Support the engine with a garage jack.
2. Remove the following special tool.
1) [Special tool MB991895 is used]
Remove special tool MB991895.
2) [Special tool MB991928 is used]
Remove special tool MB991928.
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 front mounting bracket mounting nuts and bolts, and remove the engine front mounting bracket.
[[I]] 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 FRONT MOUNTING BRACKET INSTALLATION
1. Place a garage jack against the engine oil pan with a piece of wood in between, and install the engine front mounting bracket while adjusting the position of the engine.
2. Support the engine assembly with a garage jack.
3. Remove the chain block.
4. Use the following special tool as during removal to support the engine.
1) [Special tool MB991895 is used]
Set special tool MB991895.
2) [Special tool MB991928 is used]
Set special tool MB991928.
]]C[[TRANSAXLE ASSEMBLY INSTALLATION
1. Install the transaxle assembly.
2. Remove the front end structure bar.
]]D[[ 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 (0.12 inch). Then install the stopper securely. Apply a small amount of engine oil to the fuel line pipe and then in tall the fuel high-pressure hose.
]]E[[ DRIVE BELT INSTALLATION
CAUTION:
^ To reuse the drive belt, install it while aligning the arrow mark on the backside of belt marked at the removal with the rotating direction.
^ Check if there is no deviation of the drive belt at the angle pulley.
^ Check if the drive belt is installed onto the center of the flat face of the flat pulley.
1. Install the drive belt to each pulley as shown in the figure.
]]F[[ BRAKE BOOSTER VACUUM HOSE CONNECTION
Insert vacuum hose with its paint mark facing upward.