Replacing the Engine (Power Train on the Subframe), 4WD
Replacing the engine (power train on the subframe), 4WDTo remove
1. Drain the oil from the engine and the fluid from the gearbox.
Detach the electrical connections of the alternator (A).
2. Remove the alternator retaining bolts (B).
3. Remove the alternator bracket (A).
4. Remove the heat shield from the turbocharger (A) and catalytic converter (B).
5. Unplug the oil level sensor connector (A) and remove its clips (B).
6. Remove the bolts (C) of the lower bracket of the catalytic converter.
7. Unplug the connectors of the heated oxygen sensors.
8. Remove the upper (A) and the lower (B) oxygen sensors from the catalytic converter.
9. Remove the catalytic converter with bracket (C).
10. Tap the drive shaft (A) out of the transfer gearbox with a brass drift and mallet. Have an assistant hold the driveshaft horizontal.
Warning
Use protective goggles to protect against flying splinters of metal.
11. Remove the engine mounting (A) from the engine.
12. Remove the drive belt (B).
13. Remove the power steering pump (C). Let the servo hoses remain on the pump.
14. Unplug the control module connector (A) and detach the ground cable (B).
15. Remove the power steering fluid reservoir (C) and the servo hose clips (D).
16. Remove the A/C bracket and the turbocharger delivery pipe bracket (A).
17. Remove the power steering pump bracket (A).
18. Remove the secondary air injection pump:
^ Unplug the sensor connector (A).
^ Unplug the secondary air injection pump connector (B).
^ Remove the clips (C).
^ Remove the breather pipe bolt (D).
^ Secondary air injection pump bolts (E).
19. Detach the turbocharger delivery hose (A) from the turbocharger.
20. Detach the coolant hoses (B) from the oil cooler. Collect any fluid spill.
21. Detach the coolant pipe (C) with hoses from the thermostat housing.
22. Detach the electrical connections of the starter motor (A).
23. Remove the starter motor bolts (B).
24. Aut: Remove the bolts (A) holding the torque converter in place.
25. Remove the wiring harness (A) between the starter motor and alternator as well as the one from the rear of the intake manifold. Release the two clips from the back of the engine and the cable duct on the gearbox.
Man: Remove the cable mounting from the gearbox and detach the reversing light switch connector.
Aut: Remove the clamp and ground cable from the plate bracket and unplug the connector from the gear selector position sensor/control module.
26. Detach the 7-pin connector (A), control module connector (B), ground cable (C) and cable duct (D) from the intake manifold. Lift away the wiring harness.
27. Remove the engine control module (A) with bracket.
28. Remove the coolant pipe (A) between the heat exchanger and thermostat housing.
29. Connect 83 92 409 Lifting yoke to the engine and unload with an engine lift.
30. Remove the bolts (A) holding the torque arms to the subframe.
31. Raise the engine from the subframe.
32. Remove the support bracket (A) from the transfer gearbox.
33. Remove the rear torque arm bracket (B).
34. Remove the transfer gearbox (C).
35. Remove the lower bolts of the gearbox (A).
36. Place the engine on the floor.
37. Remove the upper bolts of the gearbox (A) and lift away the gearbox.
Aut: Press the torque converter towards the gearbox.
38. Aut: Fit 87 92 574 Holder to hold the torque converter in place.
39. Transfer the crankcase ventilation hose.
To fit
Note
Read the engine designation (L or E) and the serial number on the old engine and stamp in the equivalent on the new one.
1. Aut: Turn the torque converter so that the bolt holes align with the holes on the driver plate and turn the engine so that the oval hole in the driver is centered at the starter motor opening. Fit 87 92 574 Holder to hold the torque converter in place during fitting. Lubricate the torque converter guide pin with grease.
2. Make sure the two guide sleeves are fitted on the engine and apply grease to the guide sleeves.
3. Fit the gearbox to the engine.
Aut: Remove 87 92 574 Holder just before the gearbox is in position.
4. Tighten the upper bolts between the engine and gearbox (A).
Aut: Fit the plate bracket for the ground cable.
Tightening torque, M10: bolts, 40 Nm (30 lbf ft).
Tightening torque, M12 bolts, 70 Nm (52 lbf ft).
Tightening torque, 19 Nm (14 lbf ft)
5. Connect 83 92 409 Lifting yoke, raise the engine with an engine lift and place it on the subframe.
6. Fit the lower bolts (A) between the engine and gearbox.
Tightening torque, M10: 40 Nm (30 lbf ft)
Tightening torque, M12 70 Nm (52 lbf ft)
7. Clean the contact surfaces between the transfer gearbox and the gearbox.
8. Raise and correctly position the transfer gearbox against the gearbox.
9. Fit the transfer gearbox (A). Tighten the bolts in the illustrated order.
Tightening torque 110 Nm (81 lbf ft)
10. Carefully fit the support bracket between the transfer gearbox and engine in three stages to prevent breaks.
Tightening torque (B) stage 1: 5 Nm (4 lbf ft).
Tightening torque (C) stage 2: 20 Nm (15 lbf ft).
Tightening torque (B) stage 3: 60 Nm (44 lbf ft).
11. Fit the rear torque arm bracket (A).
Tightening torque 80 Nm (59 lbf ft).
12. Fit the bolts that hold the torque arms to the subframe.
Tightening torque, rear torque arm: 80 Nm (59 lbf ft)
Tightening torque, front torque arm: 60 Nm + 90 degrees (44 lbf ft + 90 degrees)
13. Aut: Press the torque converter against the driver plate. Fit the plug.
14. Aut: Apply Thread locking adhesive, Loctite 242 to the bolts holding the torque converter to the driver plate.
Note
Use the original bolts with corresponding washers. The torque converter will be ruined if the bolts that are used are too long.
15. Aut: Rotate the crankshaft clockwise with the pulley and tighten the bolts (A) one at a time starting with the oval hole in the driver plate.
Tightening torque: 62 Nm (46 lbf ft)
16. Fit the coolant pipe (A) between the heat exchanger and thermostat housing. Use a new O-ring coated with acid-free Vaseline.
17. Position the wiring harness.
18. Fit the wiring harness (A) between the starter motor and alternator as well as the one to the rear of the intake manifold. Fit the two clips on the back of the engine and the cable duct to the gearbox.
Man: Fit the cable mounting to the gearbox and attach the reversing light switch connector.
Aut: Fit the clamp and ground cable to the plate bracket and plug in the connector of the gear selector position sensor/control module.
19. Fit the engine control module (A) with bracket.
20. Fit the 7-pin connector (A), the control module connector (B), the ground cable (C) and the cable duct (D) to the intake manifold.
21. Fit the starter motor bolts (B).
Tightening torque 47 Nm (35 lbf ft)
22. Attach the starter motor electrical connections (A).
23. Fit the coolant pipe (C) to the thermostat housing. Use a new O-ring coated with acid-free Vaseline.
24. Attach the coolant hoses (B) to the oil cooler.
25. Attach the turbocharger delivery hose (A) to the turbocharger.
26. Fit the secondary air injection pump:
^ Fit the secondary air injection pump bolts (E).
^ Fit the breather pipe bolt (D).
^ Fit the clip (C).
^ Plug in the secondary air injection pump connector (B).
^ Plug in the sensor connector (A).
27. Fit the power steering pump bracket (A).
28. Fit the A/C bracket and the upper bracket of the turbocharger delivery pipe (A).
Tightening torque, A/C bracket: 38 Nm (28 lbf ft)
29. Remove the power steering fluid reservoir (C) and the servo hose clips (D).
30. Unplug the control module connector (A) and detach the ground cable (B).
31. Fit the power steering pump (C).
Tightening torque: 19 Nm (14 lbf ft)
32. Fit the drive belt (B).
33. Attach the engine mounting (A) to the engine.
Tightening torque 93 Nm (69 lbf ft)
34. Fit the drive shaft (A) to the transfer gearbox.
35. Fit the catalytic converter with bracket (C). Use 90 513 210 Universal paste on the nut threads.
Tightening torque, flange to turbocharger: 25 Nm (18 lbf ft)
36. Apply a light coating of 90 513 210 Universal paste to the threads of the oxygen sensors. Fit the upper oxygen sensor (A) and the lower sensor (B) to the catalytic converter.
Tightening torque 45 Nm (33 lbf ft).
37. Plug in the connectors of the heated oxygen sensors.
38. Fit the bolts (C) of the lower bracket of the catalytic converter.
Tightening torque to oil sump: 23 Nm (17 lbf ft)
39. Plug in the oil level sensor connector (A) and fit its clips (B).
40. Fit the heat shield to the catalytic converter (B) and turbocharger (A).
41. Fit the generator bracket (A).
Tightening torque, M8 22 Nm (16 lbf ft)
Tightening torque, M10: 38 Nm (28 lbf ft)
42. Fit the alternator retaining bolts (B).
Tightening torque 24 Nm (18 lbf ft).
43. Attach the electrical connections of the alternator (A).