AR01.10-P-2400PW 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: 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
CAUTION: Notes on battery
2 Remove engine suction fan ducts (1) in front of air cleaner
3 Detach air cleaner housing (2) vertically toward top from the cylinder head covers.
NOTE: Installation:
- Slightly moisten with sliding compound the retaining rubbers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor (B2/5) in the air cleaner housing.
4 Release fuel pressure through service valve (4)
NOTE: Collect fuel!
5 Dismount fuel line (5) at fuel distributor
NOTE: Collect fuel!
6 Remove hot film mass air flow sensor (B2/5)
7 Remove vacuum line (6) of purge valve
8 Pull crankcase ventilation hose (7) out of the vacuum line distributor unit of the brake booster
9 Remove vacuum line (8) of brake booster at connection (9) of intake manifold connection
NOTE: To do this, press the two clamps (arrows) together and pull out the vacuum line (8).
10 Detach vacuum line (10) at rear of intake manifold
11 Dismount both brackets of oil line level control at timing case
- Vehicles with level control code 480
12 Remove electric fan (11)
13 Attach guard plate for radiator/condenser
14 Remove poly-V-belt (12)
15 Disconnect engine wiring harness
NOTE: Guide plug of automatic transmission via the propeller shaft of the front axle gear.
16 Extract oil from expansion reservoir of power steering pump
17.1 Dismount feed line, pressure line of rack-and-pinion steering, pressure line of level control system and ground line at power steering pump
17.2 Dismount return line, pressure line of rack-and-pinion steering and ground line at power steering pump
18 Remove front and rear engine compartment paneling from below
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.
19 Drain coolant at radiator
CAUTION: Notes on coolant
20 Drain and collect engine oil
NOTE: Installation: Replace sealing ring of oil drain plug.
21 Removing left and right halfshafts
22 Disconnect connector (13) of refrigerant compressor (A9)
- Only on models fitted with air conditioning.
23 Dismount refrigerant compressor (A9)
- Only on models fitted with air conditioning.
NOTE: Three screws. Attach refrigerant compressor (A9) with connected lines onto the front axle carrier.
24 Dismount supporting clamp (15) of engine support at engine support and at oil pan top section
25 Dismount bracket (16) of 0022 sensor connectors at bottom of oil pan and tie to transmission bell
26 Detach transmission ground (W49) from transfer case
27 Remove exhaust system (18) complete AR49.10-P-7000PV
28 Dismount exhaust shielding plate (19) for propeller shaft of front axle gear
29 Release shift rod (20) at floor shift of automatic transmission and tie to the side
NOTE: For this step detach retainer (20a).
30 Dismount high-pressure line bracket of rack-and-pinion line at oil pan
NOTE: Two pieces.
31 Dismount exhaust shielding plate (21) for rear engine mount at reinforcement bridge
32 Support automatic transmission with assembly lift and transmission platform
33 Remove rear engine crossmember (22) and rear engine mount
34 Dismount front propeller shaft at transfer case
NOTE:
- The flexible coupling remains on the propeller shaft.
- Installation: Mount front propeller shaft at transfer case.
35 Loosen fitted sleeves of flexible coupling and push back propeller shaft
36 Screw engine mount onto rear engine crossmember (22) and fix rear engine crossmember with two bolts
NOTE: Do not mount engine mount at transfer case.
37 Remove assembly lift
38 Clip off clamp (23) of oil lines of automatic transmission
39 Dismount upper and lower oil line (24, 25) of automatic transmission at radiator
NOTE:
- For this step, detach circlips and seal connections!
- Installation: Check O-rings and replace if necessary.
40 Dismount bracket (25a) of lower oil line (25) of automatic transmission at longitudinal member and unclip at radiator
41 Unclip lower oil line (25) of automatic transmission at radiator
42 Dismount coolant line (26) between radiator and thermostat housing and place to the side
NOTE:
- The coolant line remains connected to the coolant expansion reservoir.
- Installation: Check condition of hose clamp and coolant line (26), replace if necessary.
43 Dismount coolant lines (27, 28) at coolant pump (29)
NOTE: Installation: Check condition of hose clamps and coolant lines (27, 28), replace if necessary.
44 Dismount coolant line (30) at rear of radiator tank
NOTE:
- For this step, press clamp together until it latches and pull out coolant line (30).
- Installation: Check coolant line (30), replace if necessary. Replace sealing ring of coolant line (30).
45 Dismount left and right engine mount (31) at top of engine support (32)
46 Attach engine hoist to lifting eyes of the engine
47 Check, if all lines and hoses etc. have been dismounted
48 Pull engine toward front, lower toward rear and slightly raise forward
49 Raise engine further and lift out.
50 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 moving off.
- Wear closed and close-fitting work clothes.
- Do not grasp hot or rotating parts.
51 Filling and bleeding power steering pump
- Vehicles without level control Vehicles with level control code 480
52 Bleed coolant system
NOTE: Warm up the engine to normal operating temperature and fully open temperature control of heater (position "warm")
53 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.
54 Check engine oil level
55 Check oil level in automatic transmission, correct if necessary
56 Run engine and inspect for leaks
57 Perform basic programming
58 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.