AR01.10-P-2400GS Remove/Install Engine

Removing, Installing Engine

Part 1:

Part 2:

Part 3:

1 Disconnect ground cable of battery
2 Remove engine compartment paneling
3 Remove radiator (1)
4 Attach guard plate for radiator/condenser

NOTE: If AC (code 580, 581) fitted.

5 Remove coolant expansion reservoir (9)
6 Remove charge air lines (5, 6) on right and left
7 Remove air cleaner (8).
8 Remove inlet and pressure connection at compressor
9 Remove poly V-belt of basic drive (4)

NOTE: Take poly V-belt off belt pulley of power steering pump and of AC compressor, if fitted, and attach at engine.

10 Unbolt power steering pump (232)

NOTE: Attach at side in engine compartment with lines connected.

DANGER:
- Risk of explosion from ignition, risk of poisoning from inhaling and swallowing fuel, as well as risk of injury from skine and eye 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.

11 Disconnect fuel lines (17/2)
12 Disconnect engine wiring harness
13 Detach line (11) at purge control valve (Y58/1).
14 Detach vacuum line (12) at intake manifold and at brake booster.

NOTE: Remove vacuum line to brake booster complete

15 Detach coolant lines (10, 13, 14, 15)
16 Remove front exhaust system (24)
17 Remove steering shock absorber
18 Remove rear engine mounts (22)

CAUTION: Support transmission

19 Unbolt propeller shaft (20) at transmission

NOTE: Driven wheels must be clear and free to rotate.

20 Detach cable for park lock interlock (66) If automatic transmission 722.6 fitted

CAUTION:
- Only in selector lever position "P"
- Only if automatic transmission 722.6 fitted

NOTE: Installation: Adjust cable for park lock interlock

21.1 Detach shift rods (21) at transmission
22.2 Separate plug connection of electric control unit at transmission
- Automatic transmission 722.6.

23 Remove slave cylinder

NOTE: Attach at vehicle with line connected.

24 Unbolt engine mount (18) at front of body
25 Attach engine hoist (25) to both lifting eyes of the engine
26 Raise engine sufficiently until bolts of AC compressor are accessible from above

NOTE: Pay attention to AC lines.

27 Unbolt AC compressor (16) (arrows)

NOTE: Attach AC compressor at bottom in side of engine compartment with piping connected.

28 Raise engine further, remove
29 Install in the reverse order
30 Inspect cooling system for leaks

DANGER:
- Risk of accident from vehicle starting oft by itself when engine running. Risk of injury from bruises and burns if you hold your hand into engine when it is started or when it is running.
- Secure vehicle to prevent it moving off by itself.
- Wear closed and close-fitting work clothes.
- Do not grasp hot or rotating parts.

31 Run engine and inspect for leaks
32 Read fault memory, erase
- Stored faults which can result from cables being disconnected or from simulation during removal and installation or test work, have to be processed and erased in the fault memories after completing the work.