Remove/Install Engine
Removal and Installation of Engine AssemblyNOTE:
- 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.
- Model 202 up to August 1994: A gasket 460 251 18 80 is inserted between the engine and transmission and a gasket 102 151 00 80 is inserted between the engine and starter to avoid water from getting in at the speration points. These gaskets should be replaced by the sealant 002 989 45 20 when performing repairs. As of August 1994 the water drain at the firewall has been modified.
Technician Safety Information
1. Remove bottom engine compartment panel.
2. Remove air cleaner.
3. Remove viscous fan and radiator.
4. Remove hot film air mass sensor.
5. Remove air cleaner cross pipe.
6. Remove air cleaner.
7. If A/C fitted, attach guard plate to condenser.
- Guard plate for radiator and condenser (approximate size): 400 x 680 x 1 mm
8. Disconnect engine wiring harness.
9. Detach vacuum pipes at switchover valves (Y3/3) and (Y4).
10. Detach vacuum pipe (arrow) at connection.
11. Detach line (B) at regeneration on switchover valve (Y58/1).
12. Unbolt vacuum line (1a) at brake servo unit (1).
13. Remove cable duct cover (18).
14. Open fuel filler cap (to release pressure in fuel tank).
15. Disconnect fuel pipes (17/2) and (17/3) at fuel distributor
16. Seal fuel pipes (17/2) and (17/3) with union (01) (shop-made).
17. Detach Bowden cable of accelerator control.
18. Extract oil from power steering pump reservoir with hand-pump (5). Refer to Steering and Suspension System.
19. Unbolt the power steering pump (or tandem high pressure pump) suction and pressure oil pipes (arrows).
NOTE: Bleed pressurized oil pump (level part) of tandem pump.
20. Disconnect coolant hose (4) and (6).
21. Remove poly V-belt (37).
22. Unbolt AC compressor (7) with piping connected, attach to side of engine compartment.
23. Remove exhaust system (2).
24. Drain coolant at crankcase.
25. Unbolt front propeller shaft (8) at transmission.
26. Push propeller shaft (8) to the rear.
27. Remove rear engine carrier (10).
28. Unbolt ground cable (11) at transmission.
29. Detach automatic transmission shift rod.
30. Detach drag link at relay levers.
31. Unscrew front engine mounts (12) at body.
32. Remove front cover (13).
33. Remove transmission dipstick.
34. Attach engine hoist to both lifting lugs of engine.
35. Tilt engine with transmission and remove.
36. Examine front engine mounts (12) and rear mounts (10).
37. Reverse procedure to install, noting the following:
- Adjust Bowden cable for control pressure.
- Check tightening torque of oil drain plugs.
- Adjust engine and transmision oil to correct level.
- Pour in anti-corrosion/anti-freeze coolant and adjust to correct level and ratio.
- Check for leaks.
- Read and erase fault memory. Refer to Powertrain Management.
NOTE: Stored faults may be caused by disconnecting cables or by simulation during removal/installation or test work, codes must be erased in the fault memories after completing operations.