REMOVAL AND INSTALLATION <4A9>


caution When the engine assembly replacement is performed, idling speed may be unstable because the MPI engine learning is not completed. To make it stable, make the system learn the idling (Refer to GROUP 00, Precautions before Service - Learning Procedure for Idling in MPI Engine ).
Pre-removal Operation
  • Fuel Line Pressure Reduction [Refer to GROUP 13B, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].
  • Front Bumper Removal (Refer to GROUP 51, Front Bumper Assembly ).
  • Engine Coolant Draining (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).
  • Engine Oil Draining (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).
  • Transmission Oil Draining (M/T: Refer to GROUP 22A, On-vehicle Service - Transmission Oil Replacement ) (Automated Manual Transmission: Refer to GROUP 22C, On-vehicle Service - Transmission Oil Replacement ).
  • Air Cleaner and Air Intake Hose Removal (Refer to GROUP 15, Air Cleaner ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A, Battery ).
  • Alternator Assembly Removal (Refer to GROUP 16, Charging System - Alternator ). <Vehicles with A/C>
  • Drive Shaft Assembly Removal (Refer to GROUP 26, Drive Shaft Assembly ).
  • Radiator Assembly Removal (Refer to GROUP 14, Radiator ).

 Post-installation Operation
  • Radiator Assembly Installation (Refer to GROUP 14, Radiator ).
  • Drive Shaft Assembly Installation (Refer to GROUP 26, Drive Shaft Assembly ).
  • Alternator Assembly Installation (Refer to GROUP 16, Charging System - Alternator ). <Vehicles with A/C>
  • Battery and Battery Tray Installation (Refer to GROUP 54A, Battery ).
  • Air Cleaner and Air Intake Hose Installation (Refer to GROUP 15, Air Cleaner ).
  • Transmission Oil Refilling (M/T: Refer to GROUP 22A, On-vehicle Service - Transmission Oil Replacement ) (Automated Manual Transmission: Refer to GROUP 22C, On-vehicle Service - Transmission Oil Replacement ).
  • Engine Oil Refilling (Refer to GROUP 12, On-vehicle Service - Engine Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14, On-vehicle Service - Engine Coolant Replacement ).
  • Drive Belt Tension Check and Adjustment (Refer to ). <Vehicles with A/C>
  • Front Bumper Installation (Refer to GROUP 51, Front Bumper Assembly ).
  • Fuel Leak Check




Removal steps

>>C<<
 ·
 Initialisation <Installation only>
<<A>>
·
 Cowl top panel (Refer to GROUP 42, Loose Panel ) <COLT>.
<<A>>
·
 Cowl top panel (Refer to GROUP 42, Loose Panel ) <COLT CZ3>.


·
 Exhaust manifold assembly (Refer to GROUP 15, Exhaust Manifold ).


1.
 Brake booster vacuum hose connection


2.
 Brake booster vacuum hose bracket connection
<<B>>
3.
 Gearshift and select cables <M/T>


4.
 Earth cable connection


5.
 Fusible link box cover


6.
 Control wiring harness connection


7.
 Earth cable connection


8.
 Engine-ECU protector


9.
 Engine-ECU <M/T> or engine automated manual transmission electronic control unit (engine-A-M/T-ECU) <Automated manual transmission> assembly mounting bolt and nut


10.
 Engine-ECU <M/T> or engine-A-M/T-ECU <Automated manual transmission> connector


11.
 Purge hose connection
<<C>>
 >>B<<
 12.
 Fuel main pipe connection


13.
 Heater hose connection




Removal steps


14.
 A/C compressor connector <Vehicles with A/C>
<<D>>
15.
 A/C compressor assembly <Vehicles with A/C>


16.
 Bell housing cover
<<E>>
17.
 Clutch release cylinder assembly <M/T>


·
 Clutch actuator <Automated manual transmission> (Refer to GROUP 22C, Transmission Assembly ).


18.
 Alternator brace <Vehicles with A/C>


·
 Engine roll stopper rod assembly (Refer to GROUP 32, Engine Roll Stopper Rod Assembly ).
<<F>>
 >>A<<
 19.
 Self locking nut and transmission mounting insulator mounting bolt
<<F>>
 >>A<<
 20.
 Self locking nut and engine mounting insulator mounting bolt
<<F>>
 >>A<<
 21.
 Engine mounting insulator
<<G>>
 >>A<<
 22.
 Engine and transmission assembly




Removal steps


23.
 Control wiring harness


24.
 Starter motor assembly
<<H>>
25.
 Transmission assembly connecting bolt
<<H>>
26.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> COWL TOP PANEL REMOVAL
caution After removing the cowl top panel, perform operation with care not to damage the windshield.

After removing the cowl top panel, attach a protection tape for the windshield on the lower area of the windshield.

<<B>> GEARSHIFT AND SELECT CABLES <M/T> DISCONNECTION

1.Disconnect the transmission assembly-transmission lever from the ends of the gearshift and select cables.
2.With the bracket installed, remove the gearshift and select cables from the transmission assembly.

<<C>> FUEL MAIN PIPE DISCONNECTION

Raise the retainer, and pull out the fuel main pipe.
note If the retainer comes off, install it securely after pulling out the fuel main pipe.

<<D>> A/C COMPRESSOR ASSEMBLY <VEHICLES WITH A/C> REMOVAL


1.With the hose installed, remove the A/C compressor assembly from the cylinder block.
2.Secure the removed A/C compressor assembly with cord or rope at a position where they will not interfere with the removal of the engine and transmission assembly.

<<E>> CLUTCH RELEASE CYLINDER ASSEMBLY <M/T> REMOVAL
1.With the hose installed, remove the clutch release cylinder assembly from the transmission assembly.
2.Secure the removed clutch release cylinder assembly with cord or rope at a position where they will not interfere with the removal of the engine and transmission assembly.

<<F>> SELF LOCKING NUT AND TRANSMISSION MOUNTING INSULATOR MOUNTING BOLT/SELF LOCKING NUT AND ENGINE MOUNTING INSULATOR MOUNTING BOLT/ENGINE MOUNTING INSULATOR REMOVAL

1.Place a cart below the engine and transmission assembly.
2.Lower the lift to the position where the weight of the engine and transmission assembly is not applied to the transmission mounting insulator and the engine mounting insulator.
3.Remove the self-locking nuts, transmission mounting insulator mounting bolt and engine mounting insulator mounting bolts.
4.
caution Because the engine assembly is installed with tilted toward the rear side, support the engine and transmission assembly after removing the engine mounting insulator.
Remove the engine mounting insulator.

<<G>> ENGINE AND TRANSMISSION ASSEMBLY REMOVAL
1.Confirm that the cable, the hose, and the harness connector are all disconnected.
2.
caution Do not bend the fuel main pipe.
Raise the body slowly with a lift, and remove the engine and transmission assembly.

<<H>> TRANSMISSION ASSEMBLY CONNECTING BOLT/ENGINE ASSEMBLY REMOVAL

1.Install the chain of special tool engine hanger balancer (MB991454) and special tool hanger (MB991527), and set the chain block.
2.Remove the transmission assembly connecting bolts.
3.
caution When lifting the engine assembly, operate with care not to lift the transmission assembly.
Lift the engine assembly slowly using the chain block, and remove the transmission assembly when the engine assembly is lifted a little.

INSTALLATION SERVICE POINTS

>>A<< ENGINE AND TRANSMISSION ASSEMBLY/ENGINE MOUNTING INSULATOR/SELF LOCKING NUT AND ENGINE MOUNTING INSULATOR MOUNTING BOLT/SELF LOCKING NUT AND TRANSMISSION MOUNTING INSULATOR MOUNTING BOLT INSTALLATION

1.Place the engine and transmission assembly on the cart below the lifted vehicle.
2.Lower the lift to the position where the mounting bolts of the engine mounting insulator and the transmission mounting insulator, and the self-locking nuts are installed.
3.Install the engine mounting insulator.
4.Tighten the new self-locking nuts of engine mounting insulator and transmission mounting insulator to the specified torque, and tighten the new mounting bolts of engine mounting insulator and transmission mounting insulator to the specified torque.
Tightening torque:

    49 ± 5 N·m <Engine mounting insulator mounting bolts and self locking nuts>
    43 ± 4 N·m <Transmission mounting insulator mounting bolt and self locking nuts>

>>B<< FUEL MAIN PIPE CONNECTION

caution After connecting the fuel main pipe, check that it has been securely installed by slightly pulling in the removal direction. At this time, also check that there is approximately 3-mm play.

>>C<< INITIALISATION
When the engine-ECU is removed, initialise the electronic-controlled throttle valve system according to the following procedure after installing the engine-ECU.
1.Turn the ignition switch from "ON" position to "LOCK" (OFF) position, and then hold "LOCK" (OFF) position for approximately 10 seconds or more.