AR01.10-P-2400PV Remove/Install Engine
Removing and installing engine
Part 1:
Part 2:
Part 3:
Shown On Engine 112 With Transmission 716.6:
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
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.
1 Disconnect ground cable of battery
2 Remove air cleaner housing (1) and the two air intake pipes (2)
NOTE:
- Remove air cleaner by lifting vertically up and off the cylinder head covers. Only on model 203.065/265
- Installation: Slightly moisten the retaining rubbers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor in the air cleaner housing with sliding compound.
3 Remove suction fan (3)
4 Remove poly V-belt (4).
5 Remove hot film mass air flow sensor (B2/5)
6 Disconnect vacuum line (5) at rear of intake manifold
7 Detach vacuum line (6) of purge valve
8 Disconnect vacuum line of brake booster at connection (7) of intake manifold
NOTE: To do this, press the two clamps (arrows) together and pull out the vacuum line.
9 Disconnect engine wiring harness
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.
10 Disconnect fuel line (8) at fuel rail
NOTE: Release fuel pressure through service valve.
- Collect fuel!
11 Extract oil from power steering pump (10) expansion reservoir (9)
12 Detach return flow line (11) from power steering pump (10) expansion reservoir (9)
NOTE:
- Seal connections!
- Installation: Check condition of hose clamp and return line (11), replace if necessary.
13 Disconnect pressure line (12) at power steering pump (10)
NOTE:
- Seal connections!
- Installation: Replace O-ring of pressure line.
14 Disconnect ground lead (13) from power steering pump (10)
15 Remove engine compartment paneling
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.
16 Drain coolant at radiator.
CAUTION: See notes on coolant.
17 Drain and collect engine oil.
NOTE: Installation: Replace sealing ring of oil drain plug.
18 Remove front exhaust system (14) at right and left exhaust manifold
NOTE: Installation:
- On vehicles with engine damage, the front exhaust system must be examined for swarf before installing and any swarf present must be removed.
- Replace bolts.
- Inspect rivet nuts in exhaust manifold, replace if necessary.
19 Remove exhaust bracket (15)
CAUTION: Installation: Replace tapping plates (16) and nuts.
20 Remove propeller shaft (17) at transmission
21 Take off selector lever rod (19) at transmission
- Only with transmission 722.6.
NOTE: Installation: Check fuse (20), replace if necessary.
22 Remove engine crossmember (18) with mount
- Only on transmission 716.6
NOTE: Support transmission with car jack for this step.
23 Detach selector cable (37) at transmission
- Only on transmission 716.6
NOTE: First of all remove cover (38).
24 Lower transmission slightly
- Only on transmission 716.6
CAUTION: Lower transmission only far enough until the center shift (39) and the shift rod (40) are accessible.
25 Remove locking pin (41) and detach center shift (39)
- Only on transmission 716.6
CAUTION: Installation: Check safety bolt (41), replace if necessary.
26 Unhook shift rod (40)
- Only on transmission 716.6
NOTE: Installation: Slightly grease ball socket (42) of gearshift linkage.
27 Install engine cross member (18) together with mount
- Only on transmission 716.6
DANGER:
- Risk of poisoning from swallowing brake fluid. Risk of injury from brake fluid coming into contact with skin and eyes.
- Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.
28 Disconnect line (43) of hydraulic clutch
- Only on transmission 716.6
NOTE:
- Collect brake fluid.
- Seal connections
- Installation: Bleed clutch system.
CAUTION: See Brake fluid notes.
29 Detach connection hoses (21) at oil lines (22) and fit together with connection fitting (23)
NOTE: Seal connections.
30 Unscrew engine mount (25) bolts (24) at front axle carrier
31 Remove refrigerant compressor (36)
NOTE: Attach refrigerant compressor at bottom in engine compartment with lines connected.
32 Disconnect refrigerant compressor (36) plug (35)
33 Remove coolant line (26) at thermostat housing (27)
NOTE: Installation: Check condition of hose clamp and coolant line (26), replace if necessary.
34 Disconnect coolant line (28) at expansion reservoir (29)
NOTE: Installation: Check condition of hose clamp and coolant line (28), replace if necessary.
35 Detach coolant line (30, 31) at coolant pump (32)
NOTE: Installation: Check condition of hose clamps and coolant lines (30, 31), replace if necessary.
36 Detach coolant line (33) at radiator tank
NOTE:
- Push back clamp (34) until it engages and pull out coolant line (33).
- Installation: Check coolant line, replace if necessary.
- Replace seal of coolant line.
37 Attach guard plate for radiator/condenser
38 Support transmission with car jack
39 Remove engine crossmember (18) with mount
40 Attach engine hoist to lifting eyes of the engine
41 Lower engine to the rear and lift out
NOTE: Lower support (car jack) below transmission for this step.
42 Install in the reverse order
43 Bleed coolant system
NOTE: Warm up engine to operating temperature and set temperature control of heater to warm.
44 Inspect cooling system for leaks
CAUTION: Bring engine with new cylinder head gaskets first of all to operating temperature, otherwise it is not assured that the engine is fully filled with coolant.
45 Check engine oil level
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.
46 Check oil level in automatic transmission and correct if necessary
47 Run engine and inspect for leaks
48 Read diagnostic trouble code memory and erase.