AR01.10-P-2400Q Remove/Install Engine
Removing and Installing Engine
Shown on Model 209, Part 1:
Shown on Model 209, Part 2:
Shown on Model 209, 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 Position selector lever of automatic transmission on neutral
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 air cleaner housing (1) and the two air intake pipes (2)
- Detach air cleaner housing (1) vertically upward from the cylinder head covers.
NOTE: Installation: Lightly coat the rubber retainers on the cylinder head covers and the sealing ring of the hot film mass air flow sensor (82/5) in the air cleaner housing with sliding compound.
4 Remove suction fan
5 Remove poly V-belt
6 Remove hot film mass air flow sensor (B2/5)
7 Detach vacuum line purge valve -> z(9) at intake manifold
8 Disconnect brake booster vacuum line from intake manifold connection piece (10)
- To do this, press the two clamps (arrows) together and pull out the vacuum line.
9 Disconnect engine wiring harness
DANGER:
- Risk of explosion from fuel igniting, risk of poisoning from inhaling and swallowing fuel as well as risk of injury to eyes and skin from 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 line (8) at fuel rail
NOTE: Release fuel pressure through service valve
- Collect fuel
11 Suction off oil from power steering expansion reservoir (7) of power steering pump (4)
12 Remove power steering return line (6) at power steering expansion reservoir (7) of power steering pump (4)
- Seal connections
NOTE: Installation: Check condition of hose damp and power steering return line (6), replace if necessary.
13 Remove power steering high pressure line (3) at power steering pump (4)
CAUTION: Seal connections, in order to prevent foreign matter from entering!
NOTE: Installation: Replace O-ring of pressure line.
14 Remove ground line (5) of power steering pump (4)
15 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.
16 Drain coolant at radiator
CAUTION: Read notes on coolant.
17 Drain and collect engine oil
NOTE: Installation: Replace sealing ring of oil drain plug.
18 Remove and install complete exhaust system as of exhaust manifold flange connection (24)
- On vehicles with engine damage the front exhaust system must be examined for swarf and any swarf present must be removed before installing.
- Replace bolts. Inspect rivet nuts in exhaust manifold, replace if necessary, Replace rivet nuts in exhaust manifold.
19 Remove exhaust bracket (27)
NOTE: Installation: Replace tapping plates and nuts.
20 Remove propeller shaft (17) at transmission
21 Remove selector lever rod (22) at transmission
NOTE: Installation: Check fuse (21), replace if necessary.
22 Disconnect ground line (20) from body
23 Remove rear engine mount (18)
- Leave rear engine mount (18) at transmission, only unscrew bolts of rear engine mount (26) from engine crossmember (25).
24 Slacken engine crossmember (25) from body
NOTE: Only remove the four outer bolts of the engine crossmember (19), slacken the two middle ones by a 1/4 revolution.
25 Unscrew bolts of front engine mount (23) at front axle carrier
26 Remove refrigerant compressor (15)
- Attach refrigerant compressor (15) with lines connected at the bottom in the engine compartment
27 Disconnect connector of refrigerant compressor (15)
28 Remove upper coolant hose (16) and lower coolant hose (14) at radiator
- Push back damp until it latches in place; pull out coolant line.
NOTE: Installation: Replace sealing rings of coolant lines.
29 Disconnect automatic oil line (13) from oil cooler
CAUTION: Seal connections, in order to prevent foreign matter from entering! Push back clamp until it latches in place; pull out coolant line.
NOTE: Installation: Replace sealing rings of automatic oil lines (13).
30 Remove coolant line at expansion reservoir
31 Disconnect coolant feed line from expansion reservoir at radiator hose connection piece (12)
32 Slacken coolant line from electrical circulation pump connection piece (11)
33 Remove heated coolant line at radiator tank
- Push back clamp until it latches in place; pull out coolant line.
NOTE: Installation: Replace sealing rings of coolant line.
34 Attach guard plate for radiator/condenser
35 Attach engine hoist to lifting eyes of the engine
36 Support transmission with car jack
37 Unscrew engine crossmember (25) from body
- Unscrew the remaining two bolts (19) of the engine crossmember.
38 Lower engine to the rear and lift out
NOTE: Lower support (car jack) below transmission for this step. Tilt engine step by step with engine hoist toward rear and extend with engine hoist to the front.
39 Install in the reverse order
40 Bleed coolant system
NOTE: Warm up engine to operating temperature and set temperature control of heater to warm.
41 Inspect cooling system for leaks
CAUTION: Bring engine with new cylinder head gaskets first of all to operating temperature, otherwise it is not assured that the engine is fully filled with coolant.
42 Check engine oil level
- Except model 209.376
NOTE: This model (209.376) has no oil dipstick. On this model, the oil fill level is digitally checked in the instrument cluster.
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
46 Render electrical system operational
- See Perform basic programming.