Engine/Transmission, Removing
Engine/transaxle, removing
Special tools:
999 7077 Jimmy bar 999 7077 Jimmy Bar
999 7298 Terminal removal tool 999 7298 Terminal Removal Tool
999 5259 SEPARATOR 999 5259 Separator
999 7062 Separator 999 7062 Separator
999 7057 Counterhold 999 7057 Counterhold
999 7076 Lever 999 7076 Lever
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.
Removal
Preparatory work
Remove:
- the battery negative lead. See: Battery, disconnecting Battery Disconnecting.
- the cover for the expansion vessel,
Removing protective plate
Note! There is a guide sleeve on the upper mounting for the plate. This must be lifted slightly so that the panel can be slid forward.
Remove the 6 screws.
Lift and slide the protective plate forward.
Remove the splash guard.
Removing the lower engine cover
Remove:
- the bolts, x6
- the lower engine cover.
Draining coolant
Open the cock on the lower left edge of the radiator.
Drain the coolant into a clean container.
Close the cock.
Removing the upper cross stay
Remove:
- the 4 screws at the suspension turrets
- the screws of the upper engine mount on the engine
- the upper cross stay.
Removing the air cleaner cover
Remove the air cleaner cover by pulling it straight up.
Disconnecting the connector
Remove:
- the 2 connectors from the engine control module (ECM); clip the band clamp to the cable harness
- the connector from the mass air flow sensor.
Removal of air filter
Remove:
- the brake vacuum hose from the vacuum pump
- the 2 screws of the fresh air hose in the front plate
- the fresh air hose
- the air cleaner by pulling it straight up.
Removing components
Remove:
- the positive lead (1) from the electrical distribution box
- the ground cable (2) between the engine and body (loosen in the body).
Remove the connector:
- at the electrical distribution box (3)
- from the brake vacuum valve. Detach the vacuum hose from the valve that leads to the brake vacuum amplifier.
Removal of parts on transmission
Remove:
- the gear selector cable using a jimmy bar 999 7077 Jimmy bar 999 7077 Jimmy Bar to break the cable loose from its ball
- the transmission control module (TCM) connector.
Removing the oil cooler hoses
Caution! Mark up the hoses.
Remove:
- the lower line of the transaxle oil cooler
- the upper line of the transaxle oil cooler.
Note! Seal the openings and collect the oil from the oil cooler in a receptacle. Do not reuse the drained oil.
Detaching radiator hoses
Detach the radiator hoses at the quick-release coupling toward the firewall.
Removing coolant hoses
Remove:
- the upper radiator hose from the distributor housing
- the lower radiator hose from the thermostat housing.
Removing the upper engine covers
Remove the upper engine covers by pulling them straight up.
Removing the cover over the servo pump
Remove:
- the 2 screws on the cover over the servo pump
- the cover.
Removing the servo oil reservoir
Remove:
- the screw on the washer fluid filler pipe; bend out the pipe
- the return line for servo oil from the clips and clamps.
Lift up the servo oil reservoir.
Remove:
- the 2 coolant hoses from the expansion tank
- the 3 ground cables from the body at the expansion tank
- the connector from the electric cooling fan.
Position the oil reservoir on the engine.
Note! Make sure no oil runs out.
Note! Make sure that the oil return line is on the correct side of the upper coolant hose that runs to the engine.
Removing the auxiliaries belt
Remove the accessory drive belt. See Auxiliaries belt/belt tensioner, replacement, B8444S Service and Repair.
Removing the ground cable
Remove the ground cable screw between the engine and body. It is located beneath the expansion tank.
Removing front assembly components
Raise the vehicle.
Remove the front wheels.
Removing the ball joint from the link arm (on both sides of the vehicle)
Remove:
- the drive shaft screw. Counterhold with a screwdriver in the brake disc cooling channels.
- the rubber sleeve in the wheel hub
- the nut between the ball joint and link arm
- the nut of the anti-roll bar link in the anti-roll bar.
Note! Counterhold with a Torx wrench so that the ball joint gaiters do not turn when the nuts are removed.
Mark the position of the track rod.
Remove the track rod end from the guide arm. Use puller: 999 5259 SEPARATOR 999 5259 Separator.
Loosen the ball joint pin from the link arm. Use: 999 7062 Separator 999 7062 Separator.
Fit the cap nut, 7062-1, on the ball joint pin.
Tighten the nut toward the link arm. Then turn it back one rotation to create play between the cap nut and the link arm. Position the puller on the link arm and detach the ball joint from the link arm.
Removing the exhaust pipe
Remove:
- the nuts at intermediate pipe joints
- the intermediate pipes; scrap the gaskets.
Removing the screws from the front propeller shaft
Caution! Mark the position of the flange against the propeller shaft.
Remove the propeller shaft screws. Use: 999 7057 Counterhold 999 7057 Counterhold.
Removing the lower steering shaft joint
Caution! Do not move the steering wheel. The contact reel in the SRS (supplemental restraint system) could be damaged.
Set the front wheels in the straight-ahead position.
Fold the floor carpet out of the way.
Bend up the outer section of the steering shaft boot.
Remove the retaining clip around the boot.
Pull the boot up.
Turn the steering wheel to gain the best possible access to the steering shaft nut.
Remove the ignition key and activate the steering wheel lock.
Remove:
- the screw securing the mounting for the steering shaft in the joint
- the joint from the steering shaft by pressing the shaft upwards.
Removing the steering gear connector
Detach the connector (blue) from the steering gear.
Draining the fuel line
Drain the fuel line. See Fuel system, draining, B8444S, B6324S Fuel System, Draining.
Detach the quick-release coupling of the fuel line at the right rear sub-frame mount. Use 999 7298 Terminal removal tool 999 7298 Terminal Removal Tool for the pressure line.
Detach the fuel return line.
Note! Seal the openings against dirt.
Removal of A/C compressor
Detach the connector from:
- the A/C compressor (x2)
Pull out the cable harness and bend it aside.
Lowering the engine/transmission unit
Caution! Ensure that the lifting table is properly centered under the engine.
Position a lifting table under the sub-frame. Secure the table against the sub-frame.
Lowering the engine/transmission unit
Remove:
- the connector from the circulation pump.
- the 4 M10 screws in the rear edge of the sub-frame brackets
- the 4 screws in the sub-frame. Lower the engine/transmission unit approx. 15 cm so that the drive shafts create a horizontal line between the hub and the transmission.
Note! Take great care that no hoses, wiring or anything else catches in the engine / gearbox unit when it is lowered.
Tap the control arms off of the ball joint pin. Use 999 7076 Lever 999 7076 Lever. Release the drive shafts from the wheel hubs by pressing the drive shafts into the hub.
Remove the 3 A/C compressor screws.
Bend out the A/C compressor and suspend it in a suitable manner.
Continue lowering the engine/transmission unit.