AR01.10-P-2400SV Remove/Install Engine
Removing and installing engine
Part 1:
Part 2:
TRANSMISSION 716.6, Part 1:
TRANSMISSION 716.6, Part 2:
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.
1 Remove air cleaner housing (1) together with the two air inlet pipes
NOTE:
- Not on model 170.466
- Removal: Detach air cleaner housing vertically toward top from the cylinder head covers.
- Installation: Slightly moisten the retaining rubbers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor in the air cleaner housing with sliding compound.
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.
2 Disconnect ground cable of battery
3 Remove electric fan (2)
4 Remove hot film mass air flow sensor (B2/5)
5 Disconnect vacuum line (3) of brake booster at rear of intake manifold
6 Detach vacuum line (4) at rear of intake manifold
7 Detach vacuum line (5) of purge valve
8 Extract oil from expansion reservoir (6) of power steering pump
9 Disconnect power steering pump ground lead (7)
10 Detach return flow line (8) at expansion reservoir (6) of power steering pump
CAUTION: Installation: Inspect condition of hose clamp and return line (8), replace if necessary.
11 Detach pressure line (9) from power steering pump
NOTE: Seal connections!
CAUTION: Installation: Replace O-ring of pressure line (9).
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.
12 Detach fuel line (10) at fuel rail
NOTE: Release fuel pressure through service valve
- Collect fuel!
13 Remove poly-V-belt (11)
14 Disconnect engine wiring harness
15 Remove engine compartment panel (12)
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.
16 Drain coolant at radiator
17 Drain and collect engine oil
CAUTION: Installation: Replace sealing rings of oil drain screw.
18 Detach connection hoses (13) at oil lines (14) and attach to connection fitting (15)
19 Disconnect front exhaust system (16) at right and left exhaust manifold
CAUTION: Installation:
- On vehicles with engine damage the exhaust system must be examined for swarf and any swarf present removed before installing.
- Replace bolts.
- Inspect rivet nuts in exhaust manifold, replace if necessary,
- Replace rivet nuts in exhaust manifold.
20 Remove exhaust bracket (17)
CAUTION: Installation: Check tapping plates, replace if necessary.
- Replace nuts.
21 Remove propeller shaft (18) at transmission
22 Take off selector lever rod (19) at transmission
CAUTION: Installation: Check fuse (20), replace if necessary.
23 Unscrew electrical plug connection
24 Separate plug connection of reversing light switch (X49/1)
25 Unscrew ground line (35)
DANGER:
- Risk of poisoning from swallowing brake fluid. Risk of injury from brake fluid coming into contact with skin and eyes.
- Pour brake fluid only into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.
26 Separate line connection for clutch control
27 Detach selector cable (39) at bracket (37), turn nut (38) in anti-clockwise direction and take off selector cable
NOTE: Installation: Grease ball joint lightly and ensure correct seating of spacer ring (40).
28 Release locking pin (41) and pull out
29 Unhook shift rod (42) at transmission
NOTE: Installation: Lightly grease ball joint.
30 Unscrew engine mount bolts (21) at front axle carrier
31 Remove coolant line (23) at coolant pump (24)
CAUTION: Installation: Check condition of hose clamp and coolant line, replace if necessary.
32 Remove coolant line (25) at coolant pump (24)
CAUTION: Installation: Check condition of hose clamp and coolant line, replace if necessary.
33 Remove coolant line (26) at thermostat housing (27)
CAUTION: Installation: Check condition of hose clamp and coolant line, replace if necessary.
34 Detach coolant line (28) at engine block
NOTE: Pull clamp (29) up and pull out coolant line (28).
CAUTION: Installation: Replace O-ring of coolant line.
35 Disconnect connector (30) of refrigerant compressor (31)
36 Take off refrigerant compressor (31)
NOTE: Attach refrigerant compressor at bottom in engine compartment with lines connected.
37 Attach guard plate for radiator/condenser
38 Support transmission with car jack
39 Remove engine crossmember (22)
40 Attach engine hoist to lifting eyes of the engine
41 Lower engine to the rear and lift out
NOTE: Lower support (car jack) below transmission for this step.
42 Install in the reverse order
43 Bleed clutch actuation
44 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.
45 Check oil level in automatic transmission and correct if necessary.
46 Run engine and inspect for leaks.
47 Read diagnostic trouble code memory and erase.