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

Removing, Installing Engine

Shown On Model 202 With Aluminium Intake Manifold, Part 1:

Shown On Model 202 With Aluminium Intake Manifold, Part 2:

1 Disconnect ground cable of battery
2 Remove engine compartment panel (16)
3 Remove radiator (12)
4 Attach guard plate for radiator/condenser
- If AC (code 580, 581) fitted

5 Remove coolant expansion reservoir
- Model 170

6 Remove charge pressure pipes (1, 2) on left and right
- Engine 111 with supercharger

7 Remove air cleaner housing (3)
8 Remove poly V-belt of basic drive (20)

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

9 Unbolt power steering pump (45)

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.

10 Disconnect fuel pipes (17/2), (17/3)
- Open fuel filler cap

11 Disconnect engine wiring harness
12 Disconnect pipe (B1) at purge control valve (Y58/1)
13 Detach throttle control cable
- Model 202 with engine 111.944/975 (with aluminium intake manifold) up to 08/96 Model 170 with engine 111.943

NOTE: Installation: Adjust throttle control

14 Disconnect vacuum pipes (19) at intake manifold and brake booster

NOTE: Remove vacuum line to brake unit complete

15 Disconnect vacuum pipes at the switchover valves (Y3/3, Y4)
- Model 202 with automatic transmission 722.4

16 Disconnect coolant hoses (5, 6) at cylinder head and at coolant pump
17 Unbolt exhaust system at exhaust manifold and transmission intermediate bearing
18 Remove steering shock absorber
- Model 170

19 Remove rear engine mount

CAUTION: Support transmission

20 Unbolt propeller shaft (42) at transmission

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

21 Detach cable for park lock interlock (66)
- automatic transmission 722.6

CAUTION: Only in selector lever position "P"

NOTE: Installation: Adjust cable for park lock interlock

22 Separate plug connection of electric control unit at transmission
- automatic transmission 722.6

23 Detach shift rods at transmission
24 Remove slave cylinder

NOTE: Attach at vehicle with line connected.

25 Unbolt engine mounts at front body
26 Attach engine hoist (38) to both lifting eyes of engine
27 Raise engine sufficiently until bolts of AC compressor are accessible from above

CAUTION: Pay attention to AC lines

28 Unbolt intake manifold support (8)
- If engines fitted with aluminium intake manifold

29 Unbolt AC compressor (7) (arrows)
- if AC (code 580, 581) fitted

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

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

DANGER:
- Risk of accident from vehicle starting off 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.

33 Run engine and inspect for leaks
34 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.