AR01.10-P-2400AB Remove/Install Engine
Removing and installing engine
Part 1:
Part 2:
Part 3:
DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer.
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.
CAUTION: See notes on self-locking nuts and bolts
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 acid-resistant gloves, clothing and goggles. Pour battery electrolyte only into suitable and appropriately marked containers.
1 Disconnect ground cable of battery.
2 Remove bottom engine compartment paneling
DANGER:
- Risk of injury to skin and eyes from scalding from escaping hot coolant. 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.
3 Drain coolant at radiator
4 Drain and collect engine oil
NOTE: Installation: Replace sealing ring of oil drain plug.
5 Unclip cover at face end of engine
6 Remove air cleaner housing (6)
NOTE: Take off intake pipes for this step.
7 Inspect both rear engine suspension lugs for marking
NOTE: Engine suspension lugs without identification must be replaced.
8 Remove fan shroud with fan (1)
9 Attach guard plate for radiator/condenser
10 Detach coolant lines (16, 17) from coolant pump
11 Detach coolant line (19) from thermostat housing
12 Detach coolant line at top of expansion reservoir
13 Pull vacuum line (4) off brake booster at rear intake pipe
14 Extract oil of power steering pump (7)
15 Detach suction and pressure oil lines from power steering pump (7)
16 Detach vacuum hose (5) at purge control valve
DANGER:
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from contact with fuel.
- No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.
17 Disconnect fuel line (3)
- Open fuel filler cap before disconnecting
18 Detach heater hose (18) from firewall
19 Disconnect engine wiring harness
20 Remove poly V-belt (2)
NOTE: Installation: Lock tensioning device with a drift or pin of 5 mm in diameter.
21 Disconnect automatic transmission oil lines (14,15)
CAUTION: Plug openings.
22 Disconnect connector from refrigerant compressor (A9)
23 Unscrew bolts of refrigerant compressor (A9)
NOTE: Attach refrigerant compressor (A9) with lines connected at bottom in engine compartment.
24 Remove front exhaust system (9)
NOTE: Support rear exhaust system.
CAUTION: Installation: On vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.
25 Detach exhaust bracket (10) from transmission
26 Release shift rod at transmission
27 Remove rear engine crossmember (12)
28 Dismount front propeller shaft (11) at transmission
NOTE:
- The flexible coupling remains on the propeller shaft.
- Installation: Mount the front propeller shaft on the transmission.
29 Loosen fitted sleeves of flexible coupling and push back propeller shaft
30 Unscrew bolts of front engine mount (13) at front axle carrier
31 Attach engine hoist to lifting eyes of the engine
32 Lower engine to the rear and lift out
CAUTION: Ensure that the rear of the engine does not touch the firewall.
33 Install in the reverse order
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.
34 Filling and bleeding power steering pump
35 Bleed coolant system
NOTE: Warm up engine to operating temperature and set temperature control of heater to warm.
36 Inspect cooling system for leaks
CAUTION: If fitting new cylinder head gaskets, bring engine to operating temperature beforehand. Otherwise the complete filling of the engine with coolant is not assured.
37 Check engine oil level
38 Check oil level in automatic transmission and correct if necessary
39 Run engine and inspect for leaks
40 Perform basic programming
41 Read out fault memory with STAR DIAGNOSIS and erase if necessary.
NOTE: Stored faults, which may be caused by installation or test operations, must be processed and erased in the fault memories after completing the work.