AR01.10-P-2400CA Remove/Install Engine
Removing and Installing Engine
Shown On Model 112.942:
Shown On Engine 112.942, Part 1:
Shown On Engine 112.942, Part 2:
Shown On Engine 112.942, Part 3:
Shown On Engine 112.942, Part 4:
Modification Notes:
DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.
CAUTION: See notes on self-locking nuts and bolts.
1 Remove engine trim panel
2 Inspect both rear engine lifting eyes for marking
NOTE: Engine suspension lugs without identification must be replaced.
DANGER:
- Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries
- No fire, sparks, naked flames or smoking. Wear protective gloves, acid-resistant clothing and safety glasses. Pour battery electrolyte only into suitable and appropriately marked containers.
3 Disconnect ground cable of battery
NOTE: The battery is located in the right of the engine compartment.
NOTE: Installation:
- After connecting, read out fault memory, encode radio and normalize power windows.
- Vehicles with stationary heater, adjust time display on stationary heater.
4 Remove air baffle (23)
NOTE: Only Engine 113.942.
DANGER:
- Risk of injury to skin and eyes suffering scalding from contact with hot coolant spray. Risk of poisoning from swallowing coolant.
- Do not open cooling system unless coolant temperature is below 90 degrees C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles.
- Wear protective gloves, protective clothing and eye protection.
5 Drain coolant at radiator
NOTE: Remove coolant line of coolant -> Kpump (16) at coolant pump.
6 Drain and collect engine oil
7 Remove viscous fan (1)
NOTE: Right-hand thread.
8.1 Remove fan shroud (2).
NOTE: Unscrew bolts at bottom of fan shroud.
8.2 Remove electric fan
9 Attach guard plate for radiator/condenser
10 Remove expansion reservoir (13)
11 Remove air cleaner housing (7)
12 Remove resonance pipe (8) with resonance body (9)
NOTE:
- For this step separate connector of hot film mass air flow sensor (HFM) and unscrew resonance pipe at cylinder head cover.
- The resonance pipe is attached at the rear at the intake manifold with a plastic plate.
- Do not damage the plastic strap.
13 Remove coolant line of circulation pump -> Kcoolant pump (15) at coolant pump.
14 Remove coolant line of radiator -> Tthermostat housing (17) at thermostat housing.
15 Remove radiator
16 Detach vacuum line of brake booster (5) from brake booster to rear intake manifold
17 Suction off oil of power steering pump (19)
18 Detach return flow line and pressure line of power steering pump (19)
NOTE: Seal connections.
19 Detach vacuum line of regeneration (6) at intake manifold
DANGER:
- Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel, as well as risk of injury to skin and eyes exposed to fuel.
- No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers.
- Wear protective clothing when handling fuel.
20 Disconnect fuel line (4)
NOTE: Release fuel pressure through service valve Collect fuel.
21 Remove coolant line (14)
22 Disconnect engine wiring harness
23 Remove poly V-belt (3)
NOTE: Installation: Lock tensioning device with a drift or pin (diameter 5 mm).
24 Remove connector from A/C compressor (10)
25 Unscrew AC compressor (10) from timing case cover
NOTE: Attach AC compressor at bottom in engine compartment with lines and cables connected.
26 Remove left fender liner (24)
27 Remove shield (25)
NOTE: Only Engine 113.942 /965 /981.
28 Remove exhaust system (11) at exhaust manifold
NOTE: Installation: On vehicles with engine damage, the exhaust system must be examined for swarfs before assembling and any swarfs present must be removed, in order to avoid consequential damage.
29 Detach exhaust bracket (12) Support exhaust system for this step.
NOTE: Installation: Install new nuts.
30 Unbolt torque converter (20) from starter ring gear (21)
NOTE: Installation: The three fastening points (arrows, black) of the torque converter (20) must be aligned with the three recess clearances (arrows, white) in the starter ring gear (21).
31 Disconnect left OG3/32 sensor connector, upstream TWC (02x1) and right 0022 sensor connector, upstream TWC (G3/4x1) at transmission
NOTE: Remove cable straps.
32 Unscrew starter
NOTE: Do not disconnect electric cables.
33 Unscrew bolts at the transmission bell
NOTE:
- Engine 112.942/970. Do not unscrew the two top bolts at the transmission bell.
- Engine 113.942/965/981Do not unscrew the two bottom bolts at the transmission bell.
34 Unscrew engine mount nuts (18)
- Before Unscrewing the left engine mount, press oil line of power steering out of fixture.
35 Unscrew oil filler pipe (automatic transmission) at the right cylinder head cover
36 Attach engine hoist to lifting eyes of the engine
NOTE: Use engine removal device.
37 Raise engine
NOTE: Ensure that engine and its detachable components are not lying against the body.
38 Insert transmission support (22)
NOTE:
- The transmission support is inserted onto the crossmember and into the recess of the transmission.
- The transmission support prevents the torque converter being pulled out. At the same time, the transmission is fixed in place with the transmission support when installing the engine.
39 Unscrew the two top bolts (engine 112) or two bottom bolts (engine 113) of the transmission bell
CAUTION: Ensure, that the engine does not knock at the front against the radiator or condenser and damages it.
40 Pull out engine toward front and lift out
41 Install in the reverse order
42 Inspect cooling system for leaks
NOTE: If fitting new cylinder head gaskets, bring engine to operating temperature beforehand.
DANGER:
- Risk of accident. Accidents may result if the vehicle starts off unintentionally with the engine running. Risk of injury as working around the engine during start-up or while running may result in contusions and burns.
- Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.
43 Run engine and inspect for leaks.
44 Read diagnostic trouble code memory and erase
- Stored faults, which can result from removed lines or a simulation during installation or test work, have to be processed and erased in the fault memories after completing the work.