Removal and Replacement

- For oil capacity of new/used engine,
- For tools and equipment needed,

NOTE:
Raise engine hood into 90 °C position and engage left detent lever (arrow).
Remove and install engine with transmission at an inclination of approx. 45°

Removal

Drain Plug, Left (2):

Drain Plug, Right (2):

1 Drain coolant.

CAUTION: The drain plugs (2) are arranged at the left and right of the cylinder crankcase. The lateral crankshaft bearing cap bolts (arrows) should not be confused with the coolant drain plugs.





2 On vehicles with air conditioning or automatic climate control, these should be drained and hoses disconnected at the pipe pair (arrow).
3 Remove radiator and fan. Cooling System
4 Remove complete exhaust system. Exhaust System









5 Evacuate power steering pump reservoir.
6 Disconnect pressure hose on power steering
7 Disconnect all coolant, vacuum, oil, fuel and electrical lines and other connections leading to the engine.
8 Unscrew cable for TDC transmitter from diagnostic socket.
Remove screw (4) and pull out transmitter (3).
9 Disconnect control shaft.





10 Unscrew attaching screws (arrow) at left and right of engine mount.





Model 107 shown

11 Remove engine shock absorbers left and right. Drive Belts, Mounts, Brackets and Accessories
12 Attach engine hoist cables to the lifting eyes.





13 Remove rear engine cross member or bulkhead with engine mount.
14 Disconnect drive shaft from transmission.
15 Loosen connections on transmission.
16 Lift out engine at an inclination of 45 °.

Installation

CAUTION: When installing a new engine after a previous bearing failure, carefully flush oil hoses, renew oil cooler. Disassemble and clean oil damper.

17 Check engine mounts, coolant, vacuum, oil and fuel hoses, renew if required.

CAUTION: When installing the refrigerant compressor carrier (steel version) it is important to ensure stress-free assembly.

The carrier (steel version) must be checked for distortion. It must rest evenly on all contact points of the cylinder crankcase without gap. This condition should be checked before tightening the bolts.









The bolts must be tightened in the following sequence:

a) Install bolts (17, 6 and 5) finger-tight.
b) Tighten bolts (17) at engine front.
c) Tighten bolt (6) and nut (5) at side of engine.

18 Install and connect engine.
19 Install rear engine mount without tension. Tighten set screw with 30 Nm.
20 Ensure that all drain plugs are tight.
21 Fill in oils (exchange engines and overhauled engines initial operation oil according to sheet Specifications), coolant and refrigerant.
22 Check cooling system with leak tester for leaks. Check antifreeze capacity of coolant.
23 Connect control linkage and check function.
24 Clean air filter and renew if necessary.
25 Clean air cleaner and renew if necessary.
26 Set idle speed and exhaust gas value.