Removal and Replacement
NOTE: Remove and install engine together with transmission.Removal Procedure
Moving Hood Into Vertical Position:
1 Set the hood vertical.
2 Disconnect battery negative terminal.
3 Remove fan.
Alternator Connection:
4 Unplug cable connector (327) at alternator.
Pressure Pump Connections:
5 On models with self leveling suspension detach lines for pressure oil pump at cylinder head (arrows).
Condenser Shield:
6 If equipped with air conditioning: install guard plate (arrow) to evaporator of air conditioning system.
Firewall Seal Removal:
7 Pull off rubber strip (1) above fire wall. Take out clips (arrows), fold fixture upwards.
#50 Connector:
8 Unplug cable connector (50) at the plug connection.
9 Unbolt battery positive terminal.
Terminal 30 Connection:
10 Disconnect terminal (30) at cable connector and pull cable through component compartment wall and place over engine.
Engine Harness Connections:
11 Disconnect engine wiring harness at the individual connections and place over the component compartment wall.
Engine Harness Connections, B11/2, B2, X56 And W11:
12 Detach twin connector (B11/2) for engine coolant temperature sensor. Unbolt engine ground (W11). Unplug throttle body switch connector (X56). Unplug volume air flow sensor position indicator (B2).
Engine Harness Connections, Y1, Y6 And Y8:
13 Unplug start valve (Y8). Unplug electrohydraulic actuator (Y1). Unplug idle air control valve (Y6).
Engine Harness Connection, S27/2:
14 Unplug deceleration shutoff microswitch (S27/2).
Engine Harness Connections, TD, N1/2, R17, X11 And X24:
15 Unplug connector for crankshaft position sensor on ignition control module (N1/2). Unplug vacuum line (2) and 4-pin connector (3).
16 Unbolt terminal TD at terminal block of diagnostic connector (X11). Unscrew diagnostic connector (X11) and unplug on the bottom the grey cable for TDC pulse generator.
Cruise Control Connection:
17 On models equipped with cruise control, unplug connector (arrow).
Coil Wire Connection:
18 Unplug ignition cable 4 (arrow) at ignition distributor.
Fuel Evaporative Emission Control Vacuum Connections:
19 Detach vacuum lines (arrows) for fuel evaporative emission control system.
Ground Cable At Intake Manifold:
20 Unbolt ground cable at intake manifold (arrow).
Accelerator Cable Connection:
21 Detach Bowden cable (30) for accelerator control. Press plastic guide (arrow) Out of its seat in the fulcrum lever (13) to perform this step, and take Bowden cable (30) Out of the slot in the fulcrum lever.
Fuel Supply And Return Line Connections:
22 Reduce fuel pressure in the fuel lines by briefly opening fuel tank cap. Unbolt fuel lines (379 and 380).
Fuel Line Connection Tool:
NOTE: To prevent fuel flowing out of the disconnected fuel lines, both fuel lines can be plugged with a fitting (01, shop-made).
Heater Hose Connection:
23 Disconnect engine coolant hose (68) for heater supply line at the cylinder head.
Brake Booster Vacuum Line Connection:
24 Disconnect vacuum line for brake booster at intake manifold (arrow).
A/C Compressor Connection:
25 On models with A/C compressor, disconnect electric lead at A/C compressor, (arrow).
A/C Piping Group Connection:
26 Disconnect piping group (170) at the cylinder head (arrows).
27 Extract oil from the reservoir for power steering.
28 Disconnect oil lines at power steering pump.
29 On models with A/C compressor, remove poly V-belt.
30 Remove and install tensioning device for V-belt.
31 Unbolt belt pulley for high pressure pump of power steering (arrows).
32 Unbolt V-bracket (145) for power steering pump and A/C compressor (arrows).
^ Tightening torque: 25 Nm (18.5 ft lbs)
33 Unbolt power steering pump (arrows) and place to the side with the lines connected.
^ Tightening torque: 25 Nm (18.5 ft lbs)
34 Unbolt A/C compressor (425) at the supporting bracket and place to the side with lines connected. Unbolt bracket (b).
^ Tightening torque bolts (149b): 25 Nm (18.5 ft lbs)
^ Tightening torque bolts, bracket (b): 25 Nm (18.5 ft lbs)
35 Attach engine hoist into the suspension lug of the engine. Adjust engine hoist so that the engine can be raised horizontally.
36 Disconnect all remaining lines, e. g. vacuum, oil, fuel lines and electric cables, running to the engine.
37 Insert guard plate (arrow) between component compartment and engine.
38 Unbolt exhaust at the exhaust manifold (arrows).
^ Tightening torque: 25 Nm (18.5 ft lbs)
39 Unbolt exhaust holder (50 and 51) at the exhaust and transmission.
^ Tightening torque: 25 Nm (18.5 ft lbs)
40 Remove lambda sensor at exhaust pipe. Remove cover (arrow) to perform this step.
41 Remove exhaust system.
42 Unbolt engine supporting bracket (12).
^ Tightening torque, bolts: 25 Nm (18.5 ft lbs)
^ Tightening torque, nut: 70 Nm (52 ft lbs)
43 Unbolt shield (arrows).
44 Unbolt drive shaft. Loosen the bolts (7) and nut (7a) to perform this step.
^ Tightening torque: 45 Nm (33 ft lbs)
NOTE: Flexible coupling remains on drive shaft.
45 Loosen clamping nut (2a) (wrench waf 41/46). Push drive shaft back as far as possible.
^ Tightening torque: 45 Nm (33 ft lbs)
46 Detach speedometer shaft at transmission. Remove bolt (404) to perform this step.
47 Unbolt ground cable (149) at transmission.
^ Tightening torque: 45 Nm (33 ft lbs)
48 Detach shift rods at transmission (arrows). Take the clip locks off the transmission shift levers to perform this step.
49 If equipped with automatic transmission, turn white plastic lock on starter lockout, backup light switch (53) approx. 45° to the right and unplug cable connector.
50 Unplug cable (arrow) at the kickdown solenoid valve.
51 Remove both bolts (22) for engine mounting.
^ Tightening torque: 40 Nm (30 ft lbs)
52 Lift out engine together with transmission at an angle of approx. 45°.
INSTALLATION PROCEDURE
- Install in the reverse order, paying close attention to INSTALLATION NOTES and TIGHTENING TORQUES.
- Check front and rear engine mounts.
- Check fluid levels adjust to correct levels if necessary.
- Check for leaks with engine running.
INSTALLATION NOTES:
^ Adjust Accelerator Bowden cable.
^ Adjust oil level of power steering to correct level with the specified oil. With the engine running, top oil up to the mark. Turn steering several times from full lock to full lock. The power steering oil level at normal operating temperature, approx. 80°C (176°F) is approx. 18 - 26 mm (0.7-1.02 in) below the top edge of reservoir. The power steering oil level cold, approx. 20°C (68°F) should be between the Min. and Max. markings.
TIGHTENING TORQUES:
Fan to engine coolant pump: 25 Nm (18.5 ft lbs)
Engine support bracket: Bolt 25 Nm (18.5 ft lbs), Nut 70 Nm (60 ft lbs)
Exhaust pipe to exhaust manifold: 25 Nm (18.5 ft lbs)
Exhaust bracket to transmission: 25 Nm (18.5 ft lbs)
Hexagon bolt of belt pulley to power steering pump: 25 Nm (18.5 ft lbs)
Bracket for A/C compressor to oil sump: 10 Nm (7.5 ft lbs)
Bracket for A/C compressor to A/C compressor: 25 Nm (18.5 ft lbs)
V-bracket for power steering pump and A/C compressor: 25 Nm (18.5 ft lbs)
Power steering pump to supporting bracket: 25 Nm (18.5 ft lbs)
Propeller shaft to transmission: 45 Nm (33 ft lbs)
Clamping nut to spline end of propeller shaft: 45 Nm (33 ft lbs)
Ground cable to transmission: 45 Nm (33 ft lbs)
Engine mount to axle carrier: 40 Nm (30 ft lbs)