Remove/Install Engine

NOTE:
- Numbers in parentheses ( ) indicate a component or tool in the associated illustration.
- In the case of engine damage involving damage to the pistons, valves etc., parts may have got in as far as the catalytic converter, or pre-catalytic converter.
- When replacing the engine, it is essential to remove such parts otherwise they will be pulsed back into the cylinders as a result of the gas vibrations in the exhaust system and may once again cause engine damage. In addition, these parts may cause mechanical damage to the catalytic converter.
- It is therefore essential to remove any foreign bodies in the exhaust system when dealing with such types of engine damage. Catalytic converters which have been damaged must be replaced.
- Tighten oil pipes to air cooler to 30 Nm.
- Tighten knock sensors to crankcase to 20 Nm.

Preliminary work:
- First, Technician Safety Information
- Remove bottom engine compartment panel.
- Remove air-cleaner.
- Remove radiator.
- Remove viscous fan coupling.

Removing and Installing engine with Transmission:
1. Disconnect ground cable at battery.

Installation Note: Encode radio.

2. On Model 140, normalize power windows.

3. Attach guard plate to condenser of A/C system.





4. Unbolt air-to-oil cooler pipes at air-to-oil cooler (arrows).





On Model 140, unbolt oil cooler pipes at body (arrows).
5. Remove poly V-belt.





6. Extract oil from the reservoir the power steering pump with the priming pump for extracting oil.

Installation Note: Check fluid level of power steering system. Fill up power steering with the specified fluid. Top up fluid to the marking with the engine sunning. Turn steering several times from hail left to full right lock. When fluid is at normal operating temperature, it must extend to about 20 mm below the edge of the reservoir; when fluid is cold to 60 mm below the marking.





7. Detach A/C compressor of air conditioning system from the engine. Unscrew bolls (35) and nuts (for attaching pipe assembly); attach A/C compressor to the side at the bottom of the engine compare merit with the pipes connected.





8. Unbolt suction and pressure oil pipes at power steering pump and tandem high pressure pump. respectively (arrows).

Installation Note: For tandem pump, bleed pressure oil pump (level section) of tandem pump.





9. Unbolt delivery pipe of level pump (1), unscrew M8 bolts (3) of metal bracket (2) and press pressure pipe out of the metal brackets (arrows).
10. Briefly open filler cap in fuel tank to release the pressure.





11. Unbolt fuel pipes (arrow) and seal with special tool 000 589 40 37 00. Counterhold the connection fitting (1) when slackening the fuel pipe.





12. Detach Bowden cable (30) from accelerator control lever (9). Compress plastic clip (28) and pull out Bowden cable.

Installation Note: Adjusting Bowden cable.

13. Detach heater hoses and vacuum pipes in the engine compartment, pull off vacuum pipe at 2-way valve.
14. On Model 124, 129, detach connector from the oil level gauge and from the oil pressure sensor. Slacken all cable stamps of the engine wiring harness. Detach all connectors along the engine wiring harness. Remove engine wiring harness





15. On Model 140, remove component compartment cover (3), open cable duct (1) and remove righthand side.





16. On all models, unplug connectors (items X26/17 and M16/1x1) of the engine wiring harnesses. Press ratchet (arrow) and turn to release the connector (16/1x1).
17. Place engine wiring harnesses on the engine.





18. At the ignition control module, unplug crankshaft position sensor connector (L5), LH control module connector (B), knock sensors connector (A16) and detach vacuum pipe (arrow).

19. On model 124, Detach suction pipe of the evaporative emission control system from the connector on the lefthand wheelhouse.
20. On model 124, 129, 140, Unbolt diagnostic socket (X11), detach cable from TD sensor on rear of diagnostic socket.





21. On Model 124, 129, disconnect wiring (327) at the generator.
22. On all models, remove exhaust system.





23. On Model 140, remove heat shields above front and under floor catalytic converter.
24. Unbolt starter wiring harness X27 and terminal 30 at screw connection X4/10 on front right of firewall from below.





25. On all models, detach propeller by unscrewing bolts (arrows).

NOTE: The propeller shaft is balanced together with the flexible joint.

26. Slacken bolts for propeller shaft intermediate bearing but do not remove.





27. Slacken clamping nut (WAF 41/46) to propeller shaft. Push back propeller shaft as far as possible. Tightening torque 30-40 Nm.

28a. If manual transmission: Take shift rods off the transmission shift levers after pressing off the clip locks. Seperate hydraulic pipe to the slave cylinder at the hose connection. Seal pipes with dummy plugs or extract fluid from the rear chamber of the combined expansion rervoir.





28b. If automatic transmission: Loosen cable strap (23) and unscrew cable (6) at the kickdown solenoid valve (61) or pull off. Unscrew fastening bolt for the pulse generator (arrow) and pull out the pulse generator.
29. Unbolt ground cable at transmission.





30. Remove connector for starter lockout switch (8).

NOTE: The connector for the starter lockout switch is secured by a locking element (white plastic ring, arrow). Before pressing off the connector, the locking element must be turned up (direction of arrow). Detach shift rod (9) in the range selector lever.





31. Use two screwdrivers to carefully press off the connector (8) at the cable outlet and at the tab.





32. Unscrew connector for transmission overload protection (arrow).
33. Attach engine hoist to the lifting lugs of the engine. Adjust engine hoist so that the engine can be raised horizontally.
34. Support transmission in trolley jack or in inspection pit lift.





35. Unbolt rear engine support without engine mounts. Unscrew bolts (item 1).
36. Unscrew securing bolts (2) of the exhaust bracket (3) at the transmission.





37. Unscrew bolts (a) at the left and right front engine mounts from below.
38. Insert guard plate between component compartment wall and engine.
39. Move engine together with transmission into angled position and lift out of engine compartment by repositioning engine hoist several limes, and install in the same way.





NOTE: When tilting engine, pay attention to rear lifting lug and to oil filter (arrow).

40. Installation is performed in the reverse order, noting the following:

- On Model 140, before installing the engine, install right engine mount in front suspension, left engine mount can be installed with the engine.

- On all models, examine front and rear engine mounts.
- Examine coolant, oil and fuel hoses.
- If automatic transmission fitted: adjust cable for control pressure.
- Check tightening torque of oil drain plugs.
- Adjust oil level in engine and transmission to correct level.
- Pour in coolant, check anti-corrosion/anti-freeze agent, adjust to correct ratio.
- Check idle speed.

NOTE: If engine is replaced, read fault memory of the following control modules and erase any faults which may be stored.
- CFI control module
- LH-SFI control module (if applicable)
- DI/KSS ignition control module
- Electronic accelerator (if fitted)
- Diagnostic module (California)

Refer to Powertrain Management.