Installing Engine
Installing engine.Tools
Tools and materials
Required tools
Installing engine.
Special equipment-specific features are described in the notes.
Overview Of V6 Engine:
Lifting The Engine With A Workshop Crane:
1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier. --> '10 Lifting the engine with a workshop crane'
2. Secure the engine against tipping. To do this, attach the safety locks on the engine cross member and raise the support under the oil pan until it touches the oil pan.
3. Install the transmission and mount it on the engine.
4. Bolt the main catalytic converter holders onto the transmission cross member. Tightening torque 17 ft. lbs.
5. Remove the support from under the oil pan and remove the tipping protection from the engine cross member.
6. Clip the oxygen sensor cable of the rear oxygen sensors into the supports and place the connector on the engine.
7. Pre-fit the drive belt. Mount the drive belt on the pulleys as far as possible.
8. Position the lifting platform under the engine/transmission combination.
9. Raise the body to a comfortable working height with the platform lift.
Note:
^ Have a helper ensure the engine/transmission combination clearance when moving it into the body.
^ When moving the unit into the body, ensure that the shift cable is on the transmission.
Air-Conditioning Compressor:
^ When moving the unit into the body, fit the air-conditioning compressor at the same time.
Air Conditioning Compressor Fastening Screws:
10. Raise the engine/transmission combination into the body with the lifting platform. Ensure sufficient clearance. The insertion guides on the lifting platform must fit into the holes in the body. Fit the air-conditioning compressor when the engine is at half height.
11. Install power-steering pump (hydraulic pump).
Inserting The Engine Completely:
12. Then insert the engine completely up into the engine compartment.
Fastening Screws For Front-Axle Carrier And Engine Carrier:
13. Tighten the 6 new front-axle carrier engine carrier screws.
Fastening Screws For Transmission Cross Member:
14. Install transmission cross member.
Support On Wheel Hub:
15. Release the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.
Electric Connector To Transmission:
Connector To Transfer Box:
17. Connect electric connector -1, 2 and 3- to transmission.
Shift Cable:
18. Mount selector lever cable.
Note:
Electric Lead On Anti-Roll Bar:
^ In vehicles with an off road stabilizer, the electric lead must also be connected to the anti-roll bar.
Hydraulic Lines:
^ In addition, the two hydraulic lines (near the steering gear) must be screwed on.
Spring Bank Clamp, Servo Oil Cooler To Oil Cooler:
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Note: For vehicles with Servotronic, the electric connectors on the steering gear must also be connected.
Note: The slightly different illustrations between V8 and V6 show essentially the same actions.
20. Fit the steering column onto the steering gear.
Heat Protection Shield To Steering Gear:
21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. Tightening torque 7.5 ft. lbs..
Heater Coolant Lines On The Left Side Member:
22. Slide the heater coolant lines on the left side member and mount the space-saving clamps.
Coolant Connection Piece On The Lower Left On The Radiator:
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.
Secondary Air Line To Secondary Air Pump:
24. Fit secondary air line to the secondary air pump. The connector must engage audibly.
ATF Lines To Cooler:
25. Connect the ATF lines to the cooler. Remove the plugs and mount the lines. For details see--> '386219 Removing and installing the line for ATF cooling - chapter on "Installing"'.
Ground Point Of The Generator To The Right Side Member:
26. Mount the ground point of the generator on the right side member. Tightening torque 15 ft. lbs..
Note: The slightly different illustrations between V8 and V6 show essentially the same actions.
Catalytic Converter To Body:
27. Tighten the catalytic converter fastening on the body (figure shows two-train exhaust system for V8)--> Catalytic converter to body.
Installing Cardan Shaft:
28. Remove and align cardan shaft.
29. Push new exhaust clamps on catalytic converter.
Note: Use a transmission jack to support the exhaust system during installation.
Exhaust System On Transmission Jack:
30. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack.
Transverse Strut:
31. Install the front cross member under the radiators. To do this, tighten the four fastening screws. Tightening torque 17 ft. lbs..
Front Apron Fastening Screws On Transverse Strut:
32. Screw the front apron onto the transverse strut.
33. Lower the vehicle halfway.
Note:
Compressed Air Line:
^ In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
Sensor For Headlight Leveling System:
^ Then connect the headlight levelling system sensor.
Brake Lines In The Wheel Housings:
34. Tighten the brake lines on the left and right in the wheel housings.
Electrical Connections Of The Spring Struts:
35. Mount the electrical connections of the spring struts. To do this, connect cable -1- and then fasten supports -2 and 3-.
36. Lower the vehicle.
Note: If the fastening screws for the spring strut cannot be positioned, the spring strut can be pushed up slightly using a garage jack.
Mounting The Fastening Screws Of The Spring Struts:
Spring Strut View From The Wheel Housing:
37. Mount the 3 fastening screws on the left and right spring struts from above (engine compartment side). -arrows- --> 'Tightening torques for front axle'
Oxygen Sensor Connector On The Plenum Panel Splash Panel:
38. Connect the 4 oxygen sensor connectors at the radiator tank splash panel.
B+ Transfer Point On Left Spring Dome:
39. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine over the bolts. Tightening torque 17 ft. lbs..
Servo Line To Reservoir:
40. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
Line From Carbon Canister And Fuel Line To Plenum Panel Splash Panel:
41. Tighten the line on the plenum panel splash panel from the carbon canister -2- and the fuel line -1-. Tightening torque 26 ft. lbs. Then mount the vacuum line.
Right Spring Dome:
42. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines on the coolant reservoir and secure with spring band clamps.
Engine Wire Harness:
43. Lay the engine wiring harness into the plenum panel. Mount the rubber sleeve into the middle opening. Then guide the control unit connector to the right. Connect the control unit, connector, and ground point. Tightening torque 7.5 ft. lbs..
Fastening Screws For The Central Electrical System Box Cover:
44. Plug in the 4 connectors (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using four Torx screws.
45. Check whether the wiring harness is laid correctly. Close all fixing clips.
Bayonet Screws For Plenum Chamber Cover:
46. Mount the plenum chamber cover. Do not forget the electric connector. Mount the 4 bayonet screws -A-.
47. Fit the drive belt and check that it is positioned correctly. Then remove the locking screw.
48. Connect the upper right coolant connection piece to the radiator. The connection piece must engage audibly.
Air-Cleaner Element:
Note: The slightly different illustrations between V8 and V6 show essentially the same actions.
49. Insert the air-cleaner element.
Sheetmetal Clips:
50. Insert the air cleaners into the housing and slide on the cover from the top downwards. Then close the two respective sheetmetal clips.
Air Tube On Air Cleaner Cover:
51. Push the air tube on the air cleaner cover.
Intake Manifold To Throttle Body And Vacuum Line:
52. Mount the intake manifold. To do this, push the intake manifold onto the throttle body and mount the vacuum line at the same time. Then attach the other end to the cover of the air cleaner housing.
Air Cleaner Housing:
53. Attach the hose clamp, the electric connector on the mass air-flow meter and the 2 fastening bolts on the air cleaner housing.
Pressing Rubber Elements Onto The Ball Head Supports In The Cover:
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
Subsequent work
Installing engine - subsequent work
1. Fill and bleed the cooling system.
3. Connect battery.
4. Mount the wiper arms.
5. Mount engine compartment covers.
6. Check ATF level.
7. Bleed power-assisted steering.
8. Bleed off road stabilizer if necessary.
9. Mount front wheels.
10. Perform suspension alignment.
Engine Guard:
11. Fit engine guard.
12. Perform a test drive with the vehicle. Check the fluid level in the reservoir after the coolant circuit has cooled again and, if necessary, fill up to the max marking with coolant.
13. Check engine oil level.