Engine: Service and Repair
Engine, Removing and InstallingCAUTION: Part numbers are for reference only. Always check with your Parts Department for latest information.
NOTE: Remove engine from top with transmission attached.
Removing
CAUTION:
- Always obtain radio security code before disconnecting battery ground strap.
- Wait at least 20 seconds after switching off ignition before disconnecting battery. This will allow the platinum hot-wire in Air Mass Sensor (G 70) to burn itself clean.
- Always switch OFF ignition when disconnecting/reconnecting battery, or any part of Motronic ignition wiring system to prevent damage, to Motronic control unit (J 220).
- switch OFF ignition
- disconnect battery ground strap
NOTE: Ensure all removed electrical wiring, tie wraps, are reinstalled and positioned as originally placed.
- remove air cleaner housing
- remove front lock support
- remove front bumper
- remove radiator
- save coolant for reuse, when applicable
CAUTION: Coolant/antifreeze must not be reused when replacing engine, cylinder head, cylinder head gasket, radiator and heater core.
Manual transmission
- unbolt and disconnect hydraulic clutch cylinder
- disconnect shift cable and support bracket
Automatic transmission
- unclip and disconnect selector lever cable
- screw in a long 8.0 mm bolt into a threaded hole A on tensioner to release poly-ribbed belt tension
CAUTION: In order to prevent damage to tensioner, only screw in bolt sufficiently to release belt tension.
- remove poly-ribbed belt from power steering pump, A/C compressor
CAUTION: Do not kink or disconnect A/C refrigerant lines.
- remove AC compressor and secure to body or frame
CAUTION: Do not kink power steering hoses.
- remove power steering pump from bracket and secure to body or frame
- remove ignition cable guides and ignition cables (arrows)
- remove ignition distributor cap
- remove trim cover over cylinder head covers. and disconnect accelerator cable at throttle body and cable guide
- disconnect 42-point connector from engine wiring harness
- remove and disconnect all other alternator, starter and transmission electrical wiring, and lay to one side
- pull off all coolant, vacuum and intake hoses from engine
- disconnect inlet and return fuel lines at fuel distributor
NOTE: Carefully cover any open fuel lines to prevent spillage and contamination.
- disconnect oxygen sensor and front exhaust pipe
- disconnect and secure axle shafts
- attach engine sling as shown and take weight with crane
CAUTION: Use cotter pins on hooks and holding pins (arrows) to secure tool.
- Pulley side (left arrow), fourth hole in vertical bar at position 1 (center arrow)
- Flywheel side (right arrow), fourth hole in vertical bar at position 8
- The positions marked 1-4 on the bar must be towards the pulley side. The holes in the vertical bar are counted upwards from the hook.
- unbolt engine from engine carrier at front
CAUTION: Guide engine carefully when lifting to avoid damage to body.
- mount engine onto work bench with engine mount 3269 if it is to be disassembled
Installing
WARNING: DO NOT re-use any fasteners that are worn or deformed in normal use. Many fasteners are designed to be used only once and become unreliable and may fail when used a second time. This includes, but is not limited to, nuts, bolts, washers, self-locking nuts or bolts, circlips, cotter pins. For replacements always use new parts.
Reinstall engine in reverse order of removal, noting the following:
- check clutch release bearing for wear, replace if necessary
- lubricate clutch release bearing, driveshaft lightly with grease G 000 100
- do not lubricate release bearing guide sleeve
- check and ensure that the dowels for centering engine/transmission are in cylinder block
CAUTION: Guide engine carefully when lowering to avoid damage to driveshaft, body.
- lower engine onto mounts
- ensure tabs (arrows A) fit into opening (arrows B) on engine mounts
- hand tighten engine and transmission carrier bolts approximately 5 to 6 turns
- lightly rock or shake engine to adjust position
- fully tighten engine and transmission carrier bolts
- install V belt, Service and Repair
- reconnect all electrical connections, see appropriate wiring diagram
- adjust accelerator cable, Testing and Inspection
- refill coolant, Service and Repair
- check engine timing
- not adjustable
- check and adjust engine oil level
- check and adjust shift linkage
- check and adjust headlights, if necessary