Engine/Transmission, Removing
Engine/transmission, removingSpecial tools: 951 2945 999 5666 999 7076, 999 5972, 999 7077, 999 7076
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.
Remove:
- the air cleaner (ACL) module.
- the hose clamp on the rubber hose at the throttle body (TB). Move the rubber hose to one side
- the brake vacuum hose from the intake manifold
- dip stick with pipe.
Removing the battery
Remove:
- the battery box cover
- the battery negative lead. Disconnect the battery negative lead.
- battery positive lead
- the front surround for the battery box
- the holder for the battery
- the battery.
Removing the battery box
Remove:
- the three screws for the lower section of the battery box
- the lower section of the battery box. Disconnect the temperature sensor connector.
Removal
Removing the cable harness
Remove:
- the cover for the central electrical unit on the left-hand fender liner. Open the catch for the engine cable. Disconnect the cable
- 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
- 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 the fuel line and EVAP canister hose
Separate the quick-release fuel pressure line connector. Use: 999 5666. Separate the quick release connector on the evaporative emission system (EVAP) valve by pressing the connector together. Disconnect the connector for the heated oxygen sensors (HO2S). Disconnect the heated oxygen sensors (HO2S) from the clamps. Lower the cable harness behind 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.
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.
Pull the ball joint out of the wheel spindle. Use: 999 7076. 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 propeller shaft
Remove the propeller shaft.
Removing the lower torque rod
Remove the 3 screws securing the torque rod to the transmission
Remove the charge air pipe under the engine.
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 a universal plate under the sub-frame. Use: 999 5972. Secure the subframe against the fixture plate. Use a retaining strap.
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 screw for the heat deflector plate in the three-way catalytic converter (TWC)
- 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
Remove the auxiliaries belts. Use: 999 7109
Turn up the belt tensioners. Lift off the belts.
Remove the screws for the air conditioning (A/C) compressor. Hook the compressor on the radiator member. Lower the vehicle.
Disconnect the connector.
Separating the water hoses
Separate the hoses to the heater unit at the firewall. Turn the gray latches until the catch releases.
Removing the coolant hoses
Hint: When the coolant hoses are disconnected, water may be left in the hoses. Use a clean container to collect any coolant spillage. Disconnect the air bleed hoses when separating in the middle of the front cover plate. Disconnect the coolant hoses to the engine from the radiator. Place the expansion tank on the engine.
Removing the gear selector cable
Note: Ensure that the cable and sleeve do not crack or break.
Remove the gear selector cable from:
- the lever. Use: 999 7077
- the cable from the bracket. Move the cover sleeve backwards
- the cable bracket from the transmission. Move the cable to one side
- the oil cooler wiring from the transmission. Plug the cover and cables using plastic plugs
- the coolant hoses from the heat exchanger for the oil cooling system.
Separating the cable for the clutch cylinder (manual transmission)
Note: Seal the openings against contamination.
Hint: Depress the clutch pedal inside the vehicle. The brake fluid will stop running
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.
Disconnecting the connector
Remove the surround around the right-hand fog lamp. Use a weatherstrip tool. Disconnect the temperature connector and the pressure sensor.
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 together 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 to the lifting table using the retaining strap.
Lowering 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 vehicle 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 the 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 strip in the right-hand turret
- the screws for the limiter for the right-hand engine mounting
- the deflection limiter.
Removing the 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.
Roll the engine / transmission away for continued work.