Work Instructions Engines 116.961/.963
Group: 01Number: 243
Date: December 1989
SUBJECT:
REPLACING A LONGBLOCK ENGINE
ENGINE 116.961/.963
- longblock, remanufactured
- oil tube and dipstick
- left and right side engine bracket
- *covers for intake and exhaust manifold flanges
- *cover for oil filter bracket
- *various plugs used for protection during shipping and storage of longblock
NOTE:
All items marked with an asterisk(*) are to be mounted on engine core which will be returned to MBAG.
Use engine mounting bolts for fastening both (old and new) engines on stands for transfer of components.
Always clean contact surfaces, replace gaskets, sealing rings, washers etc. as necessary. Use break-in oil and break-in oil filter cartridge 001 184 64 25, for the new engine.
During installation, torque all bolts and nuts to specifications, check all connections for proper seating.
Suggested Procedure
1. Remove engine from vehicle.
2. Drain oil from old engine including oil filter.
3. Set up the removed engine next to the longblock for the exchange of parts and/or aggregates.
4. Set both engines to TDC of the first cylinder (important for transfer of ignition distributor).
5. Remove all items marked with an asterisk (*) listed above from the long- block (covers and plugs) and set aside for later installation on engine core.
6. Remove from old engine and set aside the following:
V-belts
Cruise control actuator with bracket
Alternator with mounting bracket
Injectors
7. Loosen clamp of coolant hose between thermostat housing and intake manifold at thermostat housing.
8. Transfer the following:
Intake manifold (as one complete assembly)
Temperature sensor/switch on thermostat housing
crankshaft pulley with vibration damper
Coolant pump pulley
TDC sensor with cable
power steering pump with bracket (unless disconnected during engine removal)
Distributor and ignition wiring
Spark plugs (check and replace if necessary)
A/C compressor with bracket and hoses
Air pump and valve
Oil filter assembly
Coolant temperature switch (located at rear of right cylinder head)
Exhaust manifold assemblies with crossover pipe including heat shields
Flex plate with ring gear
9. Install and connect the following:
Alternator with mounting bracket
Cruise control actuator with bracket
Injectors (check and renew if necessary) using new seals
10. Prepare old engine core for shipment to PDC (i.e., clean and drain engine and install items listed above with an asterisk (*) (see also step 5).
11. Install the completed longblock in vehicle and perform the necessary adjustments (ignition, accelerator linkage etc.).
Parts Information
In Case of warranty