AR01.10-P-2400R 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 injury to skin or eyes from hydraulic fluid spraying out under pressure. Risk of poisoning from swallowing hydraulic fluid.
- Release the pressure in the hydraulic system completely before starting any work on the system. Wear protective clothing and safety glasses.

CAUTION: Installation: Replace all self-locking bolts and nuts.

1 Move selector lever to position "R".

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.

2 Disconnect ground lead from battery

NOTE:
- Turn key in electronic ignition switch EIS into position "0". Key cannot be withdrawn.
- Vehicle fitted with code (889) Keyless-GO:
Switch off engine, remove Keyless Go cards from the vehicle and keep outside the range of the transmitter.
- Installation: Read out fault memory after connecting, adjust time display on combination instrument, code radio, normalize power window and activate steering angle sensor.

- Vehicles with stationary heater, adjust time display on stationary heater.

3 Remove air cleaner housing (1).

NOTE: Remove air intake pipes (1b, 1c) for this purpose and unclip cover at face end of engine (1a).

4 Inspect both rear engine suspension lugs for marking

NOTE: Engine suspension lugs without identification must be replaced.

5 Detach vacuum hose (2) to 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.

6 Disconnect fuel line (17/2)

NOTE: Release fuel pressure through service valve.

7 Disconnect engine wiring harness

NOTE: Only separation points in engine compartment.

8 Extract hydraulic fluid from both reservoirs of the tandem pump (30)
9 Disconnect feed lines (30f, 58) at tandem pump (30)
10 Disconnect high pressure expansion hose (30i) and unscrew from tandem pump

CAUTION: Installation: Install new O-ring.

11 Separate electrical connector of suction restrictor valve (Y86/1)
12 Unbolt ATF lines (3, 4) of automatic transmission at radiator

CAUTION: Seal connections.

NOTE: Installation: Check oil level, correct if required.

13 Remove fan shroud (5).
14 Attach guard plate for radiator/condenser
15 Remove poly-V belt (6)
16 Remove 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.

17 Drain coolant, pour in

NOTE: At radiator.

18 Drain and collect engine oil
19 Disconnect ABC high pressure hose (59) at tandem pump (30)

CAUTION: Installation: replace O-rings.

20 Unbolt bracket of high pressure expansion hose (30m) at oil pan
21 Remove fixtures of ABC high pressure hose (59) from refrigerant compressor, oil pan and torque converter housing
22 Remove bracket (30t)
23 Separate electrical connector of refrigerant compressor (7)
24 Unscrew bolts attaching refrigerant compressor (7)

NOTE: Attach refrigerant compressor (7) at the side in the engine compartment with lines connected.

25 Separate electrical connections of lambda and diagnosis sensors

NOTE: Unclip electric leads from retaining clips.

26 Separate flange connection of exhaust system (8) at exhaust manifold

CAUTION: Installation: On vehicles with engine damage, the exhaust system must be examined for swarf before installing and any swarf present must be removed.

27 Disconnect engine wiring harness

NOTE: Only separation points at underbody.

28 Remove bracket (9) of engine compartment paneling
29 Support transmission with transmission jack and transmission plate
30 Remove rear engine mount (10)
31 Unbolt propeller shaft (11) at transmission

NOTE: Flexible disk remains on propeller shaft.

32 Unhook shift rod (12) at transmission
33 Install rear engine support (13) without rear engine mount (10) and lower transmission onto engine support (13)
34 Unscrew bolts (14) of front engine mounts at front axle carrier
35 Open plastic clip (15a) and disconnect coolant line (15, 16) at coolant pump
36 Detach heater hose (17) from firewall
37 Attach engine hoist to lifting eyes of the engine
38 Lower engine to the rear and lift out

CAUTION: Ensure that the engine does not touch the firewall.

39 Install in the reverse order

DANGER:
- Risk of accident from the vehicle starting off by itself when the engine is 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.

40 Fill and bleed active body control (ABC)
41 Fill tandem pump and bleed
42 Inspect cooling system for leaks
43 Run engine and inspect for leaks
44 Read diagnostic trouble code memory and erase.