Remove/Install Engine
NOTE: All steps apply to all models (124, 129, 140) unless stated otherwise within a specific step.
Removal
- Remove air cleaner.
- Remove bottom engine compartment panel.
- Remove radiator, refer to Cooling System. Cooling System
- Disconnect ground cable at battery.
- Drain coolant at crankcase .
- Attach a suitable "shop made" (400 x 680 x 1 mm) guard plate at condenser.
- On Model 140: detach left Bowden cable (engine compartment lock).
- Detach heating water lines at rear of intake manifold and at connection pipe to rear of crankcase.
- Remove viscous fan clutch with fan (2), refer to Cooling System.
- Remove poly V-belt (3), refer to Drive Belt, Service and Repair. Service and Repair
- Take off fuel lines, seal with special tool 000 589 40 37 00.
Open fuel filler cap briefly beforehand.
- Detach electrical connections (engine wiring harness).
- Detach vacuum lines.
- Remove bowden cable (accelerator control).
- On Model 124: remove accelerator control linkage at rear.
- Unbolt vacuum line of brake servo unit.
- Extract oil in power steering pump reservoir, using special tool 112 589 00 72 00.
- Detach and seal oil lines of power steering pump.
- On models with air injection, detach air pump and plug connection.
- On Model 124: remove front bumper, right headlamp and air duct for left engine mount cooling .
- On Model 140: unbolt oil cooler line bracket.
- Unbolt and seal oil cooler lines at air-to-oil cooler (13) and (14), refer to Steering and Suspension.
- On Model 124: unbolt left oil cooler line (13) at oil pan.
- On models with level control, unbolt high pressure hose.
- On Model 124: unbolt left oil line, automatic transmission.
- Unbolt bolt for piping behind A/C compressor.
- Detach the A/C compressor (11), with piping connected, and place to the side.
- Disconnect plug connection for oxygen sensor (6) (lambda sensor).
- Remove exhaust system (7) complete, refer to Exhaust System, Service and Repair. Service and Repair
- Unbolt shield over starter.
- On Model 129: detach electrical connections on starter.
- Unbolt the wiring harness, starter and alternator from engine and transmission.
- On Model 124: unbolt strut below oil pan.
- Detach propeller shaft flexible coupling (8).
Replace safe-locking nuts.
NOTE: Flexible coupling remains on transmission.
- Loosen clamping nut on intermediate bearing attachment of propeller shaft: Refer to Transmission and Drivetrain.
- Unbolt ground cable at transmission.
- Remove rear engine carrier (10) without engine mount, refer to Transmission and Drivetrain.
- Unbolt bracket of exhaust at transmission.
- Detach shift rod at transmission.
- Disconnect electrical connections at transmission.
- Unbolt front engine mounts (12) on left and right from below, refer to Engine Mount, Service and Repair. Service and Repair
- On Model 124: pull off sealing strip of component compartment panel.
- Attach engine hoist at lifting eyes.
- Move engine into angled position and raise with engine hoist.
- On Model 129: unbolt wiring harness of alternator.
- Remove engine.
Installation
Reverse above procedure to install noting the following:
- Examine front and rear engine mounts.
- Examine coolant, oil and fuel hoses.
- On Models Equipped: adjust bowden cable for control pressure of automatic transmission, refer to Transmission and Drivetrain.
- Check, and adjust idle speed.
- Check tightening torque of oil drain plugs.
- Adjust oil level in engine, transmission and power steering to correct level.
- Pour in coolant, check anti-corrosion/antifreeze concentration and adjust to correct level, refer to Cooling System. Cooling System
- Check cooling system for leaks, using special tool 124 589 15 21 00, refer to Cooling System.
- Run engine and check for leaks.
NOTE:
- Faults stored as a result of disconnecting cables or simulation during removal and installation or test operations, should be processed and erased in the fault memories after completing the work.
- Re-code or normalize radio and power windows, as appropriate.
- Perform final control actuations.