Remove/Install Engine

Engine Replacement (Part 1 Of 2):

��Engine Replacement (Part 2 Of 2):

NOTE: Numbers in parentheses ( ) indicate a component or tool in the associated illustration.

REMOVAL
1. Disconnect ground cable of the battery
2. Remove bottom parts of noise encapsulation, refer to Body and Frame

WARNING:
^ Risk of scalding as a result of hot coolant spraying out
^ Do not open the cap of the expansion reservoir or radiator unless the coolant temperature is below 90°C.
^ Carefully turn cap to the first detent or 1/2 turn.
^ Wear protective clothing.

3. Remove radiator, refer to Cooling System.
4. Remove poly V-belt (8). Service and Repair
5. Attach a locally made guard plate (10) for radiator/condenser, refer to Guard Plate For Radiator/Condenser.
6. Detach vacuum pump, intake manifold, brake booster, vacuum control valve pipes (11, 31, 32, 33) of vacuum supply
7. Detach coolant hoses (12, 36) at cylinder head and thermostat housing, then detach coolant hose (366) after positioning engine at an angle.
8. Inspect condition of hose clips and hoses, replace if necessary.
9. Unbolt pipe (28, 29) of power steering pump
- Extract oil at reservoir before disconnecting the pipes.
- Models with with self-leveling suspension, drain pressurized oil system, refer to Steering and Suspension
10. Detach control pressure Bowden cable (15), if equipped, of automatic transmission
11. Disconnect engine wiring harness (21), refer to Disconnecting/Connecting Engine Wire Harness

WARNING:
^ Risk of explosion as a result of fuel vapors igniting.
^ No fire, naked flame or smoking. Avoid the creation of sparks.
^ Risk of poisoning as a result of inhaling fuel vapors and open handling of fuel.
^ Pour fuels only into the canisters provided for this purpose, and store in such canisters.
^ Risk of injury as a result of fuel splashing into eyes.
^ Wear protective gloves and, if necessary, eye protection when handling fuel.

12. Disconnect fuel pipes (90/1, 90/2)
- Open fuel filler cap to relieve tank pressurization
13. Detach linkage at trans mission
14. Unbolt AC compressor (37) without disconnecting lines.
- Attach AC compressor with piping connected at the bottom in the side of the engine compartment
15. Remove bolts (39, 40) of engine mounts and engine support
16. Connect engine lifting equipment as follows:





a. Attach engine hoist (50) to the front and rear engine lifting eye.
- Ensure that the injection pipe is not damaged when attaching to the front engine lifting eye!
- If necessary, shackle (01) as intermediate piece.
b. Adjust engine hoist so that engine is raised evenly at front and rear.
c. Carefully raise engine and pay attention to position; lower once again if necessary and adjust length of chain.
17. Raise engine (38), remove
- Ensure that the injection pipe is not damaged when attaching the front engine lifting eye

Engine Replacement (Part 1 Of 2):

��Engine Replacement (Part 2 Of 2):

INSTALLATION
1. Install in the reverse order, noting the following:
- Inspect setting of control pressure Bowden cable (15), adjust to correct setting
- Models with self-leveling suspension fill pressurized oil system, refer to Steering and Suspension.

WARNING:
^ Risk of accident as a result of vehicle starting off when engine running.
^ Secure vehicle to prevent it moving off.
^ Risk of injury as a result of bruises and burns if you insert your hands into engine when it is being started or when it is running
^ Wear appropriate work clothes when carrying out work on the vehicle.

- Inspect ATF level in automatic transmission, refer to Transmission and Drivetrain
- Inspect oil level of power steering pump, adjust to correct level
- Inspect cooling system for leaks

CAUTION: Engine with new cylinder head gasket: do not pressure-test cooling system until the engine has reached operating temperature

- Read fault memory, erase stored faults which may be caused by disconnecting cables or simulation during removal/installation or test operations, have to be processed and erased in the fault memories after completing the work, refer to Powertrain Management.
- Tighten the following components to:
- Bolt of AC compressor to bracket
- Bolts of front engine mounts to front suspension support: 40 Nm
- Bolts of rear engine mount to rear engine crossmember: 25 Nm
- Bolts of rear engine crossmember to body: 40 Nm

Commercially available tools
Designation
Make (e.g.)
6 mm socket wrench hexagon on flexible shaft for hose clips with worm drive
Hazet Guldenwerther Bahnhofstrasse 25-28 D-42857 Remscheid
7 mm socket wrench hexagon on flexible shaft for hose clips with worm drive
Hazet Guldenwerther Bahnhofstrasse 25-28 D-42857 Remscheid
Engine Hoist (self-locking)
Backer Herderstrasse D-42853 Remscheid
Shackle
Engine supporting arm
Schairer Weidenstrasse 5 72459 Albstadt