REMOVAL AND INSTALLATION


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 13C, On-vehicle Service - Fuel Pump Connector Disconnection (How to Reduce Pressurized Fuel Lines) ].
  • 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 Fluid Draining [Refer to GROUP 22A, On-vehicle Service - Essential Service (Transmission Fluid Replacement) ].
  • Air Cleaner Assembly and Air Cleaner Duct Assembly Removal (Refer to GROUP 15, Air Cleaner ).
  • Front Bumper Assembly Removal (Refer to GROUP 51, Front Bumper Assembly ).
  • Intercooler Assembly Removal (Refer to GROUP 15, Intercooler Assembly ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A, Battery ).
  • Cowl Top Panel Removal (Refer to GROUP 42, Loose Panel ) <COLT>.
  • Cowl Top Panel Removal (Refer to GROUP 42, Loose Panel ) <COLT CZ3>.
  • Strut Tower Bar Removal (Refer to GROUP 42, Strut Tower Bar ).
  • Radiator Assembly Removal (Refer to GROUP 14, Radiator ).
  • Drive Shaft Assembly Removal (Refer to GROUP 26, Drive Shaft Assembly ).
  • Front Catalytic Converter Assembly Removal (Refer to GROUP 17, Catalytic Converter ).
  • Front Exhaust Pipe Removal (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
  • Engine Roll Stopper Rod Assembly Removal (Refer to GROUP 32, Engine Roll Stopper Rod ).

 Post-installation Operation
  • Engine Roll Stopper Rod Assembly Installation (Refer to GROUP 32, Engine Roll Stopper Rod ).
  • Front Exhaust Pipe Installation (Refer to GROUP 15, Exhaust Pipe and Main Muffler ).
  • Front Catalytic Converter Assembly Installation (Refer to GROUP 17, Catalytic Converter ).
  • Drive Shaft Assembly Installation (Refer to GROUP 26, Drive Shaft Assembly ).
  • Radiator Assembly Installation (Refer to GROUP 14, Radiator ).
  • Strut Tower Bar Installation (Refer to GROUP 42, Strut Tower Bar ).
  • Cowl Top Panel Installation (Refer to GROUP 42, Loose Panel ) <COLT>.
  • Cowl Top Panel Installation (Refer to GROUP 42, Loose Panel ) <COLT CZ3>.
  • Battery and Battery Tray Installation (Refer to GROUP 15, Intercooler Assembly ).
  • Intercooler Assembly Installation (Refer to GROUP 15, Intercooler Assembly ).
  • Front Bumper Assembly Installation (Refer to GROUP 51, Front Bumper Assembly ).
  • Air Cleaner Assembly and Air Cleaner Duct Assembly Installation (Refer to GROUP 15, Air Cleaner ).
  • Transmission Fluid Refilling [Refer to GROUP 22A, On-vehicle Service - Essential Service (Transmission Fluid 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 ).
  • Fuel Leak Check
  • Drive Belt Tension Check and Assembly (Refer to ).




Removal steps

>>E<<
 ·
 Initialisation <Installation only>


1.
 Brake booster vacuum hose connection
<<A>>
2.
 Gearshift and select cables connection


3.
 Earth cable connection


4.
 Fusible link box cover


5.
 Battery cable connection


6.
 Control wiring harness connection


7.
 Earth cable connection


8.
 Engine-ECU protector


9.
 Engine-ECU connector connection
<<B>>
10.
 Engine-ECU and bracket assembly


11.
 Fuel vapour control valve hose connection


12.
 Fuel hose connection
<<C>>
 >>D<<
 13.
 Fuel main pipe connection


14.
 Vacuum hose connection


15.
 Heater hose connection


16.
 Oxygen sensor connector connection
<<D>>
 >>C<<
 17.
 Oxygen sensor




Removal steps


18.
 A/C compressor connector connection
<<E>>
 >>B<<
 19.
 A/C compressor drive belt
<<F>>
 >>B<<
 20.
 Alternator drive belt


21.
 Alternator connector connection


22.
 Alternator terminal connection


23.
 Alternator assembly


24.
 Alternator brace
<<G>>
25.
 A/C compressor and clutch assembly
<<H>>
26.
 Clutch release cylinder assembly


27.
 Transmission housing front lower cover stay
<<I>>
 >>A<<
 28.
 Self-locking nut and transmission mounting insulator mounting bolt
<<I>>
 >>A<<
 29.
 Self-locking nut and engine mounting insulator mounting bolt
<<I>>
 >>A<<
 30.
 Engine mounting insulator
<<J>>
 >>A<<
 31.
 Engine and transmission assembly




Removal steps


32.
 Control wiring harness


33.
 Starter motor assembly
<<K>>
34.
 Transmission assembly connecting bolts
<<K>>
35.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> GEARSHIFT AND SELECT CABLES 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.

<<B>> ENGINE-ECU AND BRACKET ASSEMBLY REMOVAL

1.Remove the clip of the splash shield (L.H.) shown in the figure.

2.Turn up the splash shield (L.H.), and remove the engine-ECU and bracket assembly mounting nut (lower side) shown in the figure.
3.Remove the engine-ECU and bracket assembly mounting nut (upper side), and remove the engine-ECU and bracket assembly.

<<C>> FUEL MAIN PIPE DISCONNECTION

Remove the fuel main pipe 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 main pipe.

<<D>> OXYGEN SENSOR REMOVAL

Remove the connection and clamp of oxygen sensor connector, and then use special tool oxygen sensor wrench (MB991953) to remove the oxygen sensor.

<<E>> A/C COMPRESSOR DRIVE BELT REMOVAL

1.Loosen the locking nut of the tensioner pulley
2.
caution To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Turn the adjusting bolt in the anti-clockwise direction (to the left) to remove the drive belt.

<<F>> ALTERNATOR DRIVE BELT REMOVAL

1.Loosen the nut for alternator pivot bolt and locking bolt.
2.
caution To reuse the drive belt, draw an arrow indicating the rotating direction (clockwise) on the back of the belt using chalk, etc.
Turn the adjusting bolt in the anti-clockwise direction (to the left) to remove the drive belt.

<<G>> 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 and transmission assembly cannot be hindered.

<<H>> CLUTCH RELEASE CYLINDER ASSEMBLY 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.

<<I>> 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.Remove the engine mounting insulator.

<<J>> ENGINE AND TRANSMISSION ASSEMBLY REMOVAL

1.Secure the A/C condenser assembly to the front end panel with a code to prevent the A/C condenser from falling when removing the engine and transmission assembly.
2.Confirm that the cables, the hoses, and the wiring harness connectors are all disconnected.
3.
caution Do not bend the fuel main pipe.
Raise the body slowly with a lift, and remove the engine and transmission assembly.

<<K>> TRANSMISSION ASSEMBLY CONNECTING BOLTS/ENGINE ASSEMBLY REMOVAL

1.Install the following special tools, and set a chain block.

  • Hanger (MB991527)
  • Engine hanger balancer (MB991454)
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:

    51 ± 3 N·m <Engine mounting insulator mounting self-locking nuts engine side>
    49 ± 5 N·m <Engine mounting insulator mounting bolts and self-locking nut body side>
    43 ± 4 N·m <Transmission mounting insulator mounting bolt and self-locking nuts>

>>B<< DRIVE BELT INSTALLATION

caution
  • To reuse the drive belt, install it by aligning the arrow mark on the backside of belt marked at the removal with the rotating direction.
  • Check that the notches of notched pulley and notches of drive belt are fit correctly.

>>C<< OXYGEN SENSOR INSTALLATION

1.Tighten the oxygen sensor to the specified torque by using special tool oxygen sensor wrench (MB991953).
Tightening torque: 50 ± 10 N·m
2.Connect the oxygen sensor connector and install the connector bracket.

>>D<< FUEL MAIN PIPE INSTALLATION

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.

>>E<< 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.