Remove/Install Engine

- Remove bottom engine compartment panel.
- Remove viscous fan, refer to cooling system. Cooling System
- Remove radiator, refer to cooling system.
- Remove cover over intake manifold.
- Attach "locally made" 400 x 680 x 1 mm guard plate at condenser.
- Remove poly V-belt, refer to Drive Belt, Service and Repair. Service and Repair
- Disconnect engine wiring harness. Disconnect/Connect Engine Wire Harness
- Unbolt vacuum pipe (arrow) to brake servo unit at intake manifold.
- Disconnect purge pipe (1).
- Open fuel filler cap to release pressure in fuel tank.





- Disconnect fuel pipes (17/2) and (17/3) at fuel distributor pipe, then seal with fitting (01) (shop-made).

NOTE: Use box wrench bit (02) 000 589 68 03 00 to disconnect fuel pipe (17/3) and connect.

- Extract oil from power steering pump reservoir with priming pump 112 589 00 72 00 for sampling oil.
- Disconnect suction and delivery oil pipes (arrows) at power steering pump (5).
- Pull off vacuum pipe at rear of intake manifold.
- Detach electrical wiring of O2 sensors at bracket at rear of transmission bell housing.
- If air-oil cooling fitted, unbolt oil cooler pipes (13, 14) at oil cooler.
- Unbolt A/C compressor (7) with connected piping, attach to side of engine compartment.





- Drain coolant at crankcase.
- Disconnect coolant hoses (7) and (8).
- Unbolt exhaust system (9) at exhaust manifold and transmission intermediate mount.
- Unbolt front propeller shaft (10) at transmission.
- Push propeller shaft (10) to the rear.
- Remove rear engine support (11), refer to Transmission and Drivetrain.
- Unclip transmission cable (arrow), for park lock, at transmission.

CAUTION: The cable must only be disconnected when selector lever in position -P-.

- Detach selector rod from transmission.
- Unbolt front engine mount (12) at front suspension carrier, refer to Engine Mount, Service and Repair. Service and Repair





- Attach engine hoist (04) to the three lifting eyes of the engine with engine supporting bar (05).
- Move engine with transmission into sloping position.
- Remove engine.

Installation
Reverse procedure to install, noting the following:
- Inspect front and rear engine mounts.
- Check tightening torque of oil drain plugs.
- Adjust engine and transmission oil level to correct level.
- Pour in coolant, check anticorrosion/antifreeze agent and adjust to correct concentration, refer to Cooling System. Cooling System
- Fill and bleed power steering pump.
- Run engine and check for leaks.
- Read and erase fault memory.

NOTE:
- Faults stored as a result of disconnecting cables or simulation during removal and installation or test operations, should be processed and erased in the fault memories after completing the work.
- Re-code or normalize radio and power windows, as appropriate.
- Perform final control actuations.