C635 DDCT/C635 Transaxle
If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.
The oil cooler can not be cleaned out. In the event that the engine requires rebuilding or replacement, replace the oil cooler.
Refer to COOLER, OIL, REMOVAL .
- Remove the engine cover.
- Perform the fuel pressure release procedure.
Refer to FUEL DELIVERY, STANDARD PROCEDURE .
- Recover the refrigerant from the refrigerant system.
Refer to PLUMBING, STANDARD PROCEDURE .
- Disconnect and remove the battery.
Refer to BATTERY, REMOVAL .
- Remove the battery tray assembly.
Refer to TRAY, BATTERY, REMOVAL .
- Remove the air cleaner body.
Refer to BODY, AIR CLEANER, REMOVAL .
- Disconnect the PCV hose (1) from the intake manifold and set aside.
- Disconnect the vent hose (3) from the cylinder head cover.
- Remove the three bolts (2) and remove the oil separator housing (4) from the cylinder head cover.CAUTION:
When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.
- Disconnect the vacuum hose at the brake booster.
- Raise and support the vehicle.
Refer to HOISTING, STANDARD PROCEDURE .
- Remove the belly pan.
Refer to BELLY PAN, REMOVAL .
- Remove the left and right front wheels.
- Remove the front fascia.
Refer to FASCIA, FRONT, REMOVAL .
- Drain the cooling system.
Refer to STANDARD PROCEDURE .
- Remove the two air conditioning line bracket nuts (1).
- Remove the bolt (4) and disconnect the A/C liquid line and the A/C discharge line from the A/C condenser tapping block (3). Remove and discard the dual plain seals.
- Install plugs in, or tape over, the opened refrigerant line fittings and condenser ports.
- Remove the fasteners securing the upper bumper reinforcement (1) to the frame/front end module. Repeat on the opposite side and remove the upper bumper reinforcement.
- Remove the two screws that secure the cooling module front shroud.
- Pinch the upper tabs and set the shroud aside.
- Lift the retainer clip (1) at the charge air cooler (CAC) outlet quick connect. Disconnect the CAC outlet hose (2) from the CAC outlet (3).
- Disconnect the charge air cooler (CAC) inlet hose quick connect (1).
- Unlock the bypass hose retainers (1) and set the hose (2) to the side.
- Remove the engine ground from the bulkhead to cylinder head.
- Remove the air-conditioning line support bracket at the compressor.
- Remove the air-conditioning lines from the compressor.
- Install plugs in, or tape over, the opened refrigerant line fittings and the compressor ports.
- Unplug the auxiliary water pump connector and remove the pump from its mount.
- Unplug the PCM connectors.
- Disconnect the heater core inlet and outlet hoses at the quick connects.
- Unlock the evap and fuel line retainer (1) by using a flat blade screwdriver or similar, push down and twist in one motion at the locks (2 and 3).
- Disconnect the shifter cable at the eyelet (1) and the retainer (2). Set the cable aside.
- Disconnect the boost pressure sensor connector from the throttle body inlet pipe.
- Loosen the CAC hose clamp (1).
- Remove the CAC support fastener (3).
- Remove the CAC pipe and hose (2).
- Disengage the electrical connector retainer and open the coolant hose retainer (2).
- Remove the vacuum pump bracket fasteners (1).
- Remove the vacuum pump bracket.
- Remove the vacuum line from the vacuum pump (1).
- Remove the vacuum pump bolts. Remove the vacuum pump.
- Install special tool (special tool #10299, Bracket, Engine Lifting) to the cylinder head at the vacuum pump location.
- Disconnect the upper and lower radiator hose quick connects.
- Remove the coolant bottle fasteners (2) and set the bottle (1) aside.
- Unplug the cooling fan motor connector (6).
- Unplug the cooling fan resistor connector (1).
- Release the coolant bottle hose clips (2) to allow the hose to be moved away from the fan module.
- Unplug the transmission electrical connectors.
- Unplug the afterrun pump connector and remove the pump from its mount.
- Remove the ground cable fastener (1). Remove the ground cable from the transmission case.
- Remove the cooling fan module (5).
Refer to FAN, COOLING, REMOVAL .
- Remove the exhaust pipe from the catalytic converter outlet.
- Remove the exhaust flange nuts and the flange gasket.
- Disconnect the upstream (1) and downstream (2) oxygen sensor wire harness connectors.
- Disengage the oxygen sensor wire harness from the retainer (3).
- Disconnect the horns.
- Remove the left and right headlamp assemblies.
- Unplug the left and right impact sensors (1).
- Disengage the hood latch cable from the latch assembly.
- With assistance of a helper, support the front end module (FEM). Remove the lower bolts (2) from the FEM left and right lower mounts (1). Leave the nut (3) attached to the bumper support (1).
- Remove the left and right axle shafts.
Refer to REMOVAL .
- Remove the intermediate shaft.
- Disconnect the lower coolant hose from the radiator.
- Remove the rear engine mount.
Refer to INSULATOR, ENGINE MOUNT, REAR, REMOVAL .
- Lower the vehicle.
- Reposition the main wire harness away from the engine.
- Install the engine leveling/lifting devise. Position an appropriate lifting tool to the leveler.
- Lift the engine enough to safely unbolt the transmission and engine mounts.
- Remove the left engine mount.
Refer to INSULATOR, ENGINE MOUNT, LEFT, REMOVAL .
- Remove the right engine mount.
Refer to INSULATOR, ENGINE MOUNT, RIGHT, REMOVAL .
- Lift the engine and transmission assembly from the vehicle.NOTE:
Make sure the air-conditioning lines are free of the moving components so they are not caught when lifting.