Work Instructions Engines 617.951/.952
Group: 01Number: 242
Date: December 1989
SUBJECT:
LONGBLOCK REPLACEMENT
ENGINE 617.951/952.
The LONGBLOCK comprises:
- longblock, remanufactured
- oil tube and dipstick
- left and right side engine bracket
- *cover for vacuum pump flange
- *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 615 184 00 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 long block for the exchange of parts and/or aggregates.
4. Set both engines to TDC of the first cylinder (important for transfer of fuel injection pump).
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
power steering pump (unless disconnected during engine removal)
Cruise control actuator and bracket
Oil filter and lines
Injection lines (5)
Injection pump oil feed line
Coolant pump pulley
Intake and exhaust manifold, turbocharger with oil lines and trap oxidizer (if applicable) as one unit.
7. Disconnect the fuel line fittings on top of the fuel filter, the A/C line and the vacuum line at the vacuum pump.
8. Remove the bracket for power steering pump together with fuel filter and set aside.
9. Transfer the following:
Left and right engine brackets
Vacuum pump
A/C compressor with lines
Fuel injection
NOTE:
Because fuel injection pump/engine is at TDC the alignment marks will not align
Accelerator linkage
Injectors (check and renew if necessary) using new heat shields and leak
off lines
Glow plugs
Heater hose adaptor fitting (left side of engine)
Coolant temperature switch/sensor
Bracket for TD sensor
Wiring harness for sensors and glow plugs
Alternator with bracket
Crankshaft pulley/damper
Coolant pump with thermostat housing
Turbocharger oil drain hose on upper oil pan
Engine block heater
Starter with heat shield
Engine lifting brackets at front and rear of cylinder head
10. Install in longblock and connect the following:
Bracket for power steering pump with fuel filter
Fuel injection lines
Fuel-, vacuum-, and A/C hoses
Cruise control actuator with bracket
Power steering Pump
Coolant pump pulley
Intake and exhaust manifold, turbocharger with oil lines and trap oxidizer (if applicable)
V-belts (check and renew if necessary)
11. Prepare old engine core for shipment to MBNA PDC (i.e., clean and drain engine and install items listed above with an asterisk (*) (see also step 5)
12. Install the completed longblock in vehicle and perform the necessary adjustments (injection pump timing, linkage etc.)
Parts Information
In Case of Warranty: