Installing Engine
Installing V6 3.2 l engineInstalling engine
Special equipment-specific features are described in the notes.
1. Suspend the engine at the jacking points provided on a workshop crane and set down on the front-axle carrier.
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-lb.
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.
^ When moving the unit into the body, fit the air-conditioning compressor at the same time.
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).
12. Then insert the engine completely up into the engine compartment.
13. Tighten the 6 new front-axle carrier engine carrier screws. Initial tightening: 89 ft-lb. Final tightening - torque angle: 180°
14. Install transmission cross member.
15. Release the lateral supports on the wheel hubs.
16. Lower the lifting platform slowly and remove.
17. Connect electric connector -1, 2 and 3- to transmission.
18. Mount selector lever cable.
Note:
^ In vehicles with an off road stabilizer, the electric lead must also be connected to the anti-roll bar.
^ In addition, the two hydraulic lines (near the steering gear) must be screwed on.
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.
21. Fit the heat protection shield on the steering gear by means of 2 fastening screws. Tightening torque: 7.5 ft-lb.
22. Slide the heater coolant lines on the left side member and mount the space-saving clamps.
23. Push on the coolant connection piece on the lower left on the radiator. The connection piece must engage audibly.
24. Fit secondary air line to the secondary air pump. The connector must engage audibly.
25. Connect the ATF lines to the cooler. Remove the plugs and mount the lines.
26. Mount the ground point of the generator on the right side member. Tightening torque: 15 ft-lb.
Note: The slightly different illustrations between V8 and V6 show essentially the same actions.
27. Tighten the catalytic converter fastening on the body (figure shows two-train exhaust system for V8).
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.
30. Install the exhaust system. Move the exhaust system to its installation position using a transmission jack.
31. Install the front cross member under the radiators. To do this, tighten the four fastening screws. Tightening torque: 17 ft-lb.
32. Screw the front apron onto the transverse strut.
33. Lower the vehicle halfway.
Note:
^ In the case of vehicles with air suspension, the compressed air lines must also be screwed on.
^ Then connect the headlight leveling system sensor.
34. Tighten the brake lines on the left and right in the wheel housings.
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.
37. Mount the 3 fastening screws on the left and right spring struts from above (engine compartment side).
38. Connect the 4 oxygen sensor connectors at the radiator tank splash panel.
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-lb.
40. Connect the servo line to the reservoir and mount the spring band clamp. Then fill the container with Pentosin.
41. Tighten the line on the plenum panel splash panel from the carbon canister -2- and the fuel line -1-. Tightening torque: 26 ft-lb.. Then mount the vacuum line.
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.
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-lb.
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.
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.
Note: The slightly different illustrations between V8 and V6 show essentially the same actions.
49. Insert the air-cleaner element.
50. Insert the air cleaners into the housing and slide on the cover from the top downwards. Then close the two respective sheetmetal clips.
51. Push the air tube on the air cleaner cover.
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.
53. Attach the hose clamp, the electric connector on the mass air-flow meter and the 2 fastening bolts on the air cleaner housing.
54. Press the 4 rubber elements in the cover onto the 4 ball head supports. The mounts must be felt to engage.
Subsequent work
Reworking
1. Fill and bleed the cooling system.
2. Bleed brake 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.
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.