Removal and Replacement
REMOVALMoving Hood Into Vertical Position:
1. Set the hood vertical.
2. Disconnect battery ground cable from the battery.
Lower Engine Cover:
3. Unscrew bolts (504) and remove bottom engine compartment covering (505).
4. Remove air filter.
Installation Note: Clean the air filter.
5. Remove radiator.
Radiator Guard:
6. Attach guard plate (arrow) to a/c condenser.
7. Remove poly-V.belt.
8. Remove viscous fan clutch.
Releasing Hydraulic Pressure:
9. Detach threaded connector (arrow) at high-pressure expansion hose.
10. Draw oil from the reservoir of the tandem pump with a suction pump.
Installation Note: Check power steering oil level. Fill power steering system with the specified oil. With the engine running, top oil up to the mark. Turn steering several times from full lock to full lock. When the oil is at normal operating temperature, level is approx. 20 mm below the edge of reservoir, if the oil is cold it should be 6 - 8 mm (.25 -.30 in) below the mark.
11. Disconnect oil lines (281, 529) to steering gear and oil line (601) for self-levelling suspension at the tandem pump.
Installation Note: Replace seals. High-pressure expansion hose (281) tightening torque 30 Nm (22.5 ft lbs). Return line (529) tightening torque 40 Nm (30 ft lbs).
A/C Compressor:
12. Detach air conditioning compressor from engine. Remove bolts (424), tightening torque 25 Nm (18.5 ft lbs). Secure air conditioning compressor with manifold connected at the bottom of the engine compartment to the side.
Fuel Lines:
13. Briefly open the fuel filler cap to vent the fuel tank pressure. Disconnect the fuel lines (380, 379). Keep the connector fining from turning (arrow) when detaching the fuel line (380).
Bowden Cables:
14. Detach the accelerator Bowden cable. Press plastic guide (517) out of its seat in the fulcrum lever (390) and withdraw Bowden cable (403) through the slot in the fulcrum lever. Squeeze links of the plastic clip (518) together and push clip with the Bowden cable (403) through the bracket rearward.
Installation Note: Readjust Bowden cable.
Electric Wires:
15. Disconnect electric wires. Turn nut (531) downward. Unscrew cross-head screw (530). Detach cable from the oil level gauge and from the oil pressure sensor.
Wiring Harness:
16. Release all cable straps of the engine wiring harness. Disconnect all the plug connectors along the engine wiring harness. Remove engine wiring harness (39).
17. Detach heating hoses and vacuum lines in engine compartment.
Position Sensor:
18. Detach green control line from position sensor and vacuum line at ignition control unit connector - sensor:
1. Vacuum connection
2. Control line connection
3. Connector - sensor connection
Evaporative Control System:
19. Detach vapor absorbtion line (arrow) of fuel evaporation control system from connector fitting on left wheelhouse.
Diagnostic Socket:
20. Detach terminal block terminal TD (arrow) next to diagnostic socket (X11), unbolt diagnostic socket, detach grey cable from TDC sensor on back side of diagnostic socket.
Wiring Connector:
21. Detach wiring connector (327) at alternator.
22. Remove rubber sealing strip (1) from component compartment wall.
23. Remove wiring harness cover by removing four plastic screws (arrows).
24. On vehicles with self-leveling suspension, unbolt wiring bracket at front of engine.
Oxygen Sensor:
25. Remove protective cover (455), unscrew oxygen sensor (454)
Oxygen Sensor:
26. Unbolt crossmember (524) in center tunnel, tightening torque 25Nm (18.5 ft lbs).
Driveshaft:
27. Remove driveshaft. Unscrew nut (474), withdraw bolt (473), tightening torque 45 Nm (33 ft lbs). Flexible joint (476) remains on transmission.
Intermediate Bearing:
28. Loosen bolt (494) for propeller shaft intermediate bearing, but do not remove. Tightening torque 25 Nm (18.5 ft lbs).
29. Loosen clamping nut (500) (wrench size 41/46 mm) on the driveshaft. Push driveshaft back as far as possible in direction of arrow, tightening torque 35 Nm (26 ft lbs).
Speedometer Cable:
30. Unscrew bolt (404). Withdraw speedometer cable (405) in direction of arrow.
Ground Cable:
31. Unscrew ground cable (149) at transmission.
Shift Rods:
32. With manual transmission: Press the clip locks off first and then detach shift rods from the transmission shift levers.
Shift Rod:
33. With automatic transmission: Detach shift rod at center console. Turn white plastic lock on starter lockout, backup light switch (53) approx. 45 degrees to the right and detach cable connector. Detach cable at kickdown solenoid valve.
Hydraulic Line:
34. With manual transmission: Disconnect hydraulic line (arrow) to slave cylinder at hose union. Seal lines with plugs or draw fluid from the rear chamber of the combined reservoir with a suction gun.
35. Attach engine hoist to the suspension lugs of the engine. Adjust engine hoist so that the engine can be lifted horizontally.
Radiator Guard:
36. Insert guard plate (arrow) between the component compartment wall and the engine.
37. Support transmission with car jack or inspection pit lift.
38. Remove rear engine support, tightening torque M1O 35 Nm (26 ft lbs).
Engine Mount:
39. Unscrew bolt (523) on left and right front engine mount from below, tightening torque 40 Nm (29.5 ft lbs).
40. Angle engine and transmission and lift Out of engine compartment, or install as appropriate, by readjusting engine hoist several times.
NOTE: When tilting engine at the rear suspension lug, pay attention to oil filter.
INSTALLATION
- Reverse sequence for reinstallation paying close attention to Installation Notes and torque values.
- Check engine mounts at front and rear.
- Check coolant, oil and fuel hoses.
- With automatic transmission, adjust cable for control pressure.
- Check idle speed, adjust if necessary.
- Check tightening torque of oil drain plugs.
- Correct oil level in engine and transmission.
- Top up coolant, check anti-corrosion antifreeze agent, correct freeze point.
Installation Notes:
- Clean the air filter.
- Check power steering oil level. Fill power steering system with the specified oil. With the engine running, top oil up to the mark. Turn steering several times from full lock to full lock. When the oil is at normal operating temperature, level is approx. 20 mm below the edge of reservoir, if the oil is cold it should be 6 - 8 mm (.25 -.30 in) below the mark.
- Replace seals for High-pressure expansion hose (281) tightening torque 30 Nm (22.5 ft lbs). Return line tightening torque 40 Nm (30 ft lbs).
- Readjust Bowden cable.
- Crossmember in center tunnel tightening torque 25 Nm (18.5 ft lbs).
- Driveshaft tightening torque 45 Nm (33 ft lbs).
- Propeller shaft intermediate bearing tightening torque 25 Nm (18.5 ft lbs).
- Clamping nut (wrench size 41/46 mm) on the driveshaft tightening torque 35 Nm (26 ft lbs).
- Left and right front engine mounts tightening torque 40 Nm (29.5 ft lbs).