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

Removing, Installing Engine

Shown On Model 202, Part 1:

Shown On Model 202, Part 2:

Shown On Model 202, Part 3:

1 Remove engine compartment panel (16)
2 Remove viscous fan clutch (13)

NOTE: Left-hand thread

3 Remove radiator (12)
4 Remove hot film mass air flow sensor (14)
- Models fitted with hot film mass air flow sensor

5 Remove air cleaner cross pipe (15)
6 Remove top part of air cleaner (11)
- Model 202, 208, 210

7 Remove poly V-belt (20)
- If AC fitted

8 Attach guard plate to condenser
9 Disconnect engine wiring harness
10 Detach vacuum line (82) at PEC control module (N3/6)
- Models fitted with PEC fuel injection system

11 Detach lines at purge valve (50)
- Models fitted with PEC fuel injection system

12 Disconnect pipe (B1) at purge control valve (Y58/1)
- Models fitted with HFM, ME fuel injection system

13 Detach throttle control cable

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.

14 Disconnect fuel pipes (17/2), (17/3)
- Open fuel filler cap
- Model 124: Disconnect fuel lines at fuel rail, replace seals.
- Model 202, 208, 210: Disconnect fuel lines at line connection.

15 Disconnect vacuum lines (4,19) at Intake manifold
- Model 124, 208, 210: Disconnect vacuum line (4) to brake booster at intake manifold.
- Model 202: Disconnect vacuum line (4) to brake booster at brake booster.

16 Disconnect vacuum pipes at the switchover valves (Y3/3, Y4)
- Automatic transmission 722.4

17 Unbolt lines (26, 27, 28, 29) of power steering pump

NOTE:
- Before unbolting the lines, extract oil at reservoir.
- Installation: If level control (code 217b) fitted, Drain pressurized oil system, fill

18 Disconnect coolant hoses (5, 6) at cylinder head and at coolant pump
19 Unbolt AC compressor (7) (arrows), attach
- If AC (code 580, 581) fitted

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

20 Drain coolant

NOTE: at crankcase

21 Detach shift rods at transmission
22 Separate clutch line at slave cylinder
23 Slacken clamping nut (41) of propeller shaft (42)

NOTE: Models 124, 202: Clamping nut (41) discontinued as of approx. 01/95, replace by sliding piece.

24 Unbolt propeller shaft (42) at transmission
25 Remove rear engine mount
26 Disconnect electric cables and speedometer shaft at transmission
- Model 124

27 Unbolt engine mounts at body or front axle carrier at front
28 Raise engine, remove
- Model 202: Attach engine hoist (38) to the two lifting eyes of the engine
- Model 208, 210: Remove engine with removal fixture

29 Install in the reverse order.
30 Read fault memory, erase.