Removal and installation the engine (Mitsubishi Space Star)

Warning: In Figure 4.34, elements marked with an (*) must be pre-tightened during installation and finally tightened after the vehicle has been lowered onto its wheels.

Fig. 4.34. Removable elements and engine mounting elements: 1 - Power steering pump; 2 - air conditioning compressor; 3 - engine bracket; 4 - engine

Removal

• Disconnect the wires from the battery terminals.
• Remove the hood.
• Remove the lower engine splash shield.
• Drain the coolant from the engine cooling system.
• Remove the air filter.
• Remove the charge air intercooler and intercooler hose.
• Remove the exhaust pipe.
• Remove the accessory drive belt.
• Disconnect the connectors from the camshaft position sensor, fuel pressure sensor, high-pressure fuel pump, fuel temperature sensor, fuel injectors, glow plugs, coolant temperature sensor, EGR solenoid valve, air conditioning compressor, generator and oil pressure sensor (Fig. 4.33).

Fig. 4.33. Locations of connections of connectors and hoses to the engine: 1 - camshaft position sensor connector; 2 - fuel pressure sensor connector; 3 - high pressure fuel pump connector; 4- fuel temperature sensor connector; 5 - fuel injector connector; 6 - glow plug connector; 7 - coolant temperature sensor connector; 8 - EGR solenoid valve connector; 9 - air conditioning compressor connector; 10 - generator connector; 11 - oil pressure sensor connector; 12 - vacuum hose; 13 - brake booster vacuum hose; 14 - engine cooling system hose; 15 - heater hoses; 16-fuel return hose; 17 - fuel supply hose

• Loosen the clamp and disconnect the brake booster vacuum hose.
• Disconnect the vacuum hoses.
• Loosen the clamp and disconnect the engine cooling system hose.
• Loosen the clamps and disconnect (heater hoses)
• Disconnect the fuel supply and return hoses. To prevent dirt and foreign matter from entering the fuel system, plug all open connections in the fuel system.
• Remove the bolts and remove the power steering pump along with the attached hose and bracket.

Note: Use a cord or soft wire to secure the removed power steering pump to the engine compartment so that it does not interfere with engine removal.

• Disconnect the connector, unscrew the bolts and remove the air conditioning compressor from the bracket along with the connected hoses.

Note: Use a cord or soft wire to secure the removed compressor in the engine compartment so that it does not interfere with engine removal.

• Remove the gearbox.
• Place a hydraulic jack under the engine.
• Remove the special tool used to remove the gearbox from the engine.
• Secure the engine to the crossbar and hang it on a hoist or similar device (Fig. 4.35).

Fig. 4.35. Using a crossbeam to lift the engine from the engine compartment

• Place a block of wood between the jack base and the engine oil pan and lift the engine slightly to relieve the jack from the weight of the engine, then remove the engine mount bracket.
• Make sure all wires (electrical connectors), hoses, etc. are disconnected from the engine, and then slowly lift the engine up out of the engine compartment.

Installation

• Installation is carried out in the reverse order of removal, taking into account the following.
• When installing the motor, make sure that no wires, hoses or wire connectors are pinched.
• Place a hydraulic trolley jack under the engine (inserting a wooden block between the support foot of the jacks and the engine oil pan) and install the engine support bracket, adjusting the position of the engine using the jack.
• Support the engine with a jack and disconnect the hoist.
• Install the gearbox.
• Install the air conditioning compressor.
• Install the power steering pump with the attached hose and bracket.
• Remove the plugs and connect the fuel supply and return hoses.
• Connect the heater hoses and secure them with clamps.
• Connect the brake booster vacuum hose.
• Connect the vacuum hoses.
• Connect the engine cooling system hose.
• Reconnect all previously disconnected electrical connectors.
• Install the exhaust pipe.
• Install the accessory drive belt.
• Install the intercooler and intercooler hose.
• Install the air filter.
• Fill the cooling system with coolant.
• Install the lower engine splash shield.
• Install the hood.
• With the engine installed in the engine bay of the vehicle, check the engine oil and coolant levels. Check that all previously removed wires and hoses are in place.
• Remove air from the fuel system.
• Connect the cable to the negative terminal of the battery.
• Start the engine and check for leaks.