AR01.10-P-2400CB Remove/Install Engine
Removing and installing engine
Shown On Model 210 With Engine 112, Part 1:
Shown On Model 210 With Engine 112, Part 2:
Shown On Model 210 With Engine 112, Part 3:
Only Model 208, 202 With Engine 112, 113:
DANGER:
- Risk of death. Death may result if vehicle slips or topples from the lifting platform.
- Align vehicle between the columns of the hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.
CAUTION: See notes on self-locking nuts and bolts.
1 Remove engine trim panel or air cleaner.
NOTE:
- On model 129, 202.093/033, 208.370/374/470 and 210.274/074 the air cleaner is integrated in the engine trim panel.
- Remove engine cover or air filter by lifting upwards from the cylinder head covers.
2 Inspect both rear engine suspension lugs for marking.
CAUTION: Engine lifting eyes without marking must be replaced.
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.
3 Disconnect ground cable of battery.
NOTE: Installation: After connecting the ground lead, read out DTC memory, encode radio and calibrate power windows. Vehicles with stationary heater: adjust time display on stationary heater.
4 Remove engine compartment paneling
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.
5 Drain coolant at radiator
6 Drain and collect engine oil
7 Detach connection hoses (23, 24) at oil lines (21, 22) and fit together with connection piece (25)
8 Remove viscous fan (1)
- All except model 208.365/465 with engine 112.
NOTE: Right-hand thread!
9 Remove fan shroud (2).
- On models fitted with suction fan, separate plug connection of suction fan before removing fan shroud.
10 Remove air cleaner housing (7)
- All except model 129, 202.033/093, 208.370/374/470, 210.074/274
11 Remove resonance pipe (8) with resonance body (9)
- All except model 129, 202.033/093, 208.370/374/470, 210.074/274
- Separate plug connection of hot film mass air flow sensor (HFM-SFI) for this step and
- unbolt resonance pipe at cylinder head cover.
NOTE: The resonance pipe is attached at the rear to the intake manifold with a plastic plate.
CAUTION: Do not damage plastic plate.
12 Remove hot film mass air flow sensor together with air intake pipe
13 Detach coolant lines (18,19) at coolant pump)
14 Detach coolant line (20) at thermostat housing
15 Detach coolant line at top of expansion reservoir
- Only model 208, 202
16 Remove radiator.
17 Attach guard plate for radiator/condenser
18 Detach vacuum line (5) from brake booster at rear of intake manifold
19 Extract power steering pump (15) oil
20 Disconnect ground cable at power steering pump (15)
21 Detach return flow and pressure lines of power steering pump (15)
NOTE: Seal connections.
22 Detach vacuum line (6) at intake manifold.
NOTE: Model 129
Pull off vacuum line (6) at regeneration control valve.
DANGER:
- Risk of explosion if ignition takes place, risk of poisoning caused by inhaling fuel vapors or swallowing fuel, as well as risk of injury to skin and eyes exposed to fuel.
- No fire, sparks, naked flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel.
23 Disconnect fuel line (4) at fuel rail.
NOTE: Release fuel pressure through service valve
- Collect fuel!
24 Detach coolant line (17)
NOTE: On model 202.093/033 an additional coolant line is attached at the right cylinder head.
- The coolant line of the right cylinder head runs to an external transmission oil cooler which is located on the right behind the front molding. The routing of the coolant line of the left cylinder head is the same as on the standard vehicle.
25 Disconnect engine wiring harness.
26 Remove poly V-belt (3)
NOTE: Installation: Lock tensioning device with a drift or pin (diameter 5 mm).
27 Separate plug connection of AC compressor (16)
28 Unbolt AC compressor (16) from timing case cover
NOTE: Installation: Attach AC compressor at bottom in engine compartment with lines and cables connected.
29 Detach exhaust system (10) at exhaust manifold
CAUTION: Installation: On vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.
30 Separate plug connections of sensors on right (G3/3x1) and on left (G3/4x1) and release.
- Only in Model 208, 202
31 Remove bracket (10a) of exhaust system
- All except model 129
- Support exhaust system.
NOTE: Installation: Replace nuts.
32 Unbolt clutch slave cylinder
NOTE: Do not disconnect line.
33 Detach propeller shaft (11) at transmission.
34 Release cable for park lock interlock (14)
35 Release shift rod at transmission.
36 Remove rear engine crossmember (11) at transmission
CAUTION: Support transmission for this step.
37 Unscrew bolts (13) of front engine mounts at front axle carrier.
38 Press pressure line of level control at bottom part of oil pan out of fixtures
- Only Model 129
39 Attach engine hoist to lifting eyes of the engine
CAUTION: On model 210 with engine 113 and model 208 with engine 112, 113 use the engine removal fixture!
40 Lower engine to the rear and lift out
41 Install in the reverse order
42 Inspect cooling system for leaks.
CAUTION: If fitting new cylinder head gaskets, bring engine to operating temperature beforehand.
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 from moving. Wear closed and snug-fitting work clothes.
- Do not grasp hot or rotating parts.
43 Check oil level in automatic transmission and correct if necessary
44 Run engine and inspect for leaks
45 Read diagnostic trouble code memory and erase
- Stored faults, which can result from removed lines or a simulation during installation or test work, have to be processed and erased in the fault memories after completing the work.