AR01.10-P-2400C Remove/Install Engine
Removing and installing engine
Shown On Model 210.082 With Engine 112, Part 1:
Shown On Model 210.082 With Engine 112, Part 2:
Shown On Model 210.082 With Engine 112, 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 hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer.
CAUTION: Read notes on self-locking nuts and bolts.
1 Remove engine trim panel
2 Inspect both rear engine lifting eyes for marking
CAUTION: Engine suspension lugs without identification 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:
- The battery is located below the rear seat.
- Installation: After connecting the ground cable, read fault memory, encode radio and normalize 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, pour in
6 Drain and collect engine oil
7 Remove viscous fan (1)
NOTE: Right-hand thread.
8 Remove fan shroud (2).
- On models fitted with suction fan, separate plug connection of suction fan before removing fan shroud.
9 Attach guard plate for radiator/condenser
10 Remove air cleaner housing (7)
11 Remove resonance pipe (8) with resonance body (9)
- Separate plug connection of hot film mass air flow sensor (HFM-SFI) for this step and
- unbolt resonance pipe at cylinder head cover. The resonance pipe is attached at the rear to the intake manifold with a plastic plate.
CAUTION: Do not damage plastic plate.
12 Detach coolant line (18,19) at coolant pump
13 Detach coolant line (20) at thermostat housing
14 Detach vacuum line (5) from brake booster at rear of intake manifold
15 Extract oil of power steering pump
16 Detach return flow and pressure line at power steering pump (15)
NOTE: Seal connections.
17 Detach vacuum line (6) at intake manifold
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.
18 Disconnect fuel line (4) at fuel rail
NOTE: Release fuel pressure through service valve Collect fuel.
19 Detach coolant line (17)
20 Disconnect engine wiring harness
21 Remove poly V-belt (3)
NOTE: Installation: Arrest clamping device using drift or pin (diameter 5 mm).
22 Detach connection hoses (23, 24) at oil lines (21, 22) and fit together with connection piece (25)
NOTE: Seal connections.
23 Unbolt AC compressor (16) from timing case cover
NOTE: Attach AC compressor at bottom in engine compartment with lines and cables connected.
24 Detach exhaust system (10) at exhaust manifold
NOTE: Installation: On vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.
25 Remove bracket (10a) of exhaust system
- Support exhaust system for this step.
NOTE: Installation: Replace nuts.
26 Detach vibration damper at transmission below propshaft
27 Detach propeller shaft (11) at transmission
28 Release cable for park lock interlock (14)
29 Release shift rod at transmission
30 Take off front wheels
31 Remove drive shafts (26)
NOTE: Pull drive shafts off front axle drive.
CAUTION: Do not damage seals of drive shafts.
32 Remove engine crossmember (12)
NOTE: Support transmission for this step.
33 Unscrew bolts (13) of front engine mounts at front axle carrier.
34 Separate plug connection of AC compressor (16)
35 Disconnect ground cable at power steering pump (15)
36 Attach engine hoist to lifting eyes of the engine
37 Lower engine to the rear and lift out
38 Install in the reverse order
39 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.
40 Check oil level in automatic transmission and correct if necessary
41 Run engine and inspect for leaks
42 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.
43 Check chassis alignment, align if necessary.