Engine, Removal
Engine, removal
Special tools:
999 5666 Wrench 999 5666 Wrench
999 7076 Lever 999 7076 Lever
999 5972 FIXTURE 999 5972 Fixture
999 7077 Jimmy bar 999 7077 Jimmy Bar
999 7109 Wrench 999 7109 Wrench
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Removing components
Drain the fuel system. See: Fuel system pressure release Fuel System Pressure Release.
Remove:
- the battery box cover
- the battery ground lead.
- the battery positive lead
- the front surround for the battery box
- the holder for the battery
- the battery
- the lower section of the battery box, 3.
Removal
Removing the air cleaner (ACL) module
Remove the air cleaner (ACL) module. See: Air filter module Service and Repair.
Removing the cable harness
Remove:
- The dip stick and the oil pipe
- the cover for the central electrical unit on the left-hand fender liner. Open the locking for the engine cable harness. Disconnect the cable harness
- the ground lead in the left-hand turret
- the clamp for the cable harness. Fold the cable harness out of the way
- the positive cable on the starter motor
- the clamp for the starter motor cable harness
- the ground lead on the front of the transmission.
Separating the steering shaft
Remove the screw. Lift up the steering shaft joint so that it releases from the steering gear.
Separating fuel line and EVAP canister hose
Note! Seal the openings.
Separate the quick-release fuel pressure line connector. Use: 999 5666 Wrench 999 5666 Wrench.
Separate the quick-release connector on the canister purge (CP) valve by pressing the connector together. Disconnect the connector for the heated oxygen sensors (HO2S). Disconnect them from the clamps. Lower the rear section of the engine.
Removing components, sub-frame
Remove the following on both sides:
- the front wheels
- 1 screw (1) Press in the drive shaft a little.
Removing steering arm on both sides
Slacken off the nut so that the upper edge is above the screw.
Pull the steering arm out of the wheel spindle. Use: 951 2945 Puller 951 2945 Puller.
Removing the wheel spindle
Slacken off the nut so that the upper edge is above the screw.
Remove the ball joint from the control arm. Use: 951 2945 Puller 951 2945 Puller.
Pull the ball joint out of the wheel spindle. Use: 999 7076 Lever 999 7076 Lever. Press the drive shaft out of the wheel spindle.
Draining coolant
Raise the vehicle. Remove the splash guard under the engine.
Install a hose on the drain nipple on the engine. Open the nipple and drain the coolant into a clean container. Close the nipple. Remove the hose.
Removing the lower torque rod
Remove the 3 screws securing the torque rod to the transmission.
Removing power steering pipe
Note! Clear up any oil spill.
Remove:
- the right-hand fender liner. Slacken off the 6 front screws. Fold back the fender liner
- the delivery line from the power steering pump. Seal the openings
- the return line from the servo reservoir. Seal the openings.
Remove the pipes from the mountings on the engine and the sub-frame.
Removing components on the sub-frame
Unhook the three-way catalytic converter (TWC) in the sub-frame.
Disconnect the connector for the rear heated oxygen sensor (HO2S). Detach the cable harness from the sub-frame.
Removing the sub-frame
Position a mobile jack with universal plate under the sub-frame. Use: 999 5972 FIXTURE 999 5972 Fixture.
Removing the sub-frame, continued
Remove:
- the screws for the front edge of the sub-frame
- the screws for the support brackets at the rear edge of the sub-frame
- the screws for the rear edge of the sub-frame. Carefully lower the sub-frame.
Removing the three-way catalytic converter (TWC)
Remove:
- the screws for the front SIPS member
- the SIPS member
- the nuts at the junction between the three-way catalytic converter (TWC) and the exhaust manifold. Discard the nuts
- the nuts at the junction between the three-way catalytic converter (TWC) and the exhaust system
- the catalytic converter. Remove the gaskets and discard them.
Removing air conditioning (A/C) compressor
Unhook the auxiliaries belts. Turn up the belt tensioners and lift off the belts. Use: 999 7109 Wrench 999 7109 Wrench. Remove the screws for the air conditioning (A/C) compressor. Disconnect the connector. Hang the compressor from the radiator member. Lower the vehicle.
Separating the water hose
Separate the hoses for the heater unit inside the passenger compartment. Turn the gray catches to release the locking.
Removing the coolant hose
Disconnect the air bleed hoses when separating in the middle of the front cover plate
Disconnect the coolant hoses from the radiator.
Place the expansion tank on the engine.
Removing components from the transmission
Remove the gear selector cable. Use: 999 7077 Jimmy bar 999 7077 Jimmy Bar to disconnect the cable ball joint from the lever.
Separating the cable for the clutch cylinder
Note! Seal the openings against contamination.
Hint: Depress the clutch pedal inside the car. The brake fluid will stop running.
Applies to cars with manual transmissions
Separate the cable to the clutch cylinder at the firewall. Lift up the retaining clip and separate the cable. Wipe up any spilled brake fluid.
Applies to cars with automatic transmission
Remove:
- the oil hoses for the transmission. Clean up oil spillage and seal the openings
- the coolant hoses for the oil cooling system. Collect spilled coolant and seal the openings.
Preparations for lowering the engine / transmission
Note! Ensure that the lifting table is centered under the engine / transmission for optimal weight distribution. Check that the lifting table is correctly positioned.
Position a retaining strap over the engine. Position the retaining strap on either side of the engine.
Raise the vehicle. Use a post hoist with a lifting table and stud guides. Position the lifting table against the oil pan. Use the post hoist support arms to support the engine / transmission.
Secure the engine / transmission in the lifting table with the retaining strap.
Lowering the vehicle
Open the cock for the hydraulic modulator for the lifting table.
Ask a colleague to help. Lower the vehicle at the same time as opening the lifting table compressed air unit. Stop the car immediately before the lifting table reaches its lower position.
Close the cock for the hydraulic modulator for the lifting table.
Marking the position of the engine pad
Mark the position of the engine pad on the frame member. Use a marker pen
Removing engine mounting
Using the hydraulic modulator for the lifting table, lift up the engine / transmission slightly in order to slacken off the engine mountings.
Remove:
- the ground lead in right-hand turret
- the screws for the limiter for the right-hand engine mounting
- the deflection limiter.
Removing engine mounting
Remove:
- the screws for the right-hand engine mounting in the frame member
- the engine mounting
- the screws for the engine mounting on the transmission. Carefully raise the vehicle and ensure that the air conditioning (A/C) compressor is free of the engine.
Finishing
Final rolling
Roll the engine / transmission away for continued work.