Installing Engine
Installing engine
Required tools
Installing engine
Special equipment-specific features are described in the notes.
1. Suspend the engine at the mounting points provided on a workshop crane and set down on the suspension subframe.
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 connect it to the engine.
^ Tightening torque, transmission screw fittings: 80 Nm (59 ft. lbs.).
^ Tightening torque, converter screw fittings: 85 Nm (63 ft. lbs.); replace screws.
4. Bolt the main catalytic converter holders onto the transmission cross member. Tightening torque: 23 Nm (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 holders and place the plug on the engine.
7. Pre-fit the drive belt. Mount the drive belt on the belt pulleys as far as possible.
8. Position the lift truck under the body.
9. Raise the body to a comfortable working height with the lifting platform.
Note:
^ When moving the unit into the body, ensure that the selector cable is on the transmission.
^ When moving the unit into the body, fit the air-conditioning compressor at the same time.
10. Raise the the engine/transmission combination into the body with the lift platform. Ensure sufficient clearance. The insertion guides on the lift truck must fit into the holes in the body. Fit the air-conditioning compressor when the engine is at half height. Tighten the front fastening screws (M8 x 93) to 25 Nm (19 ft. lbs.) and the rear screws (M10 x 100) to 45 Nm (33 ft. lbs.).
11. Install servo pump. Tighten the 3 fastening screws (M8 x 40) to 23 Nm (17 ft. lbs.). To tighten the front screws, turn the belt pulley in such a way that the screws can be tightened.
12. Then insert the engine fully up into the engine compartment.
Caution: Risk of damage!
^ Suspension subframe screws can break off.
^ Suspension may become loose.
^ Always replace fastening screws.
13. Tighten the six new suspension subframe engine carrier screws. Tightening torque: 100 Nm (74 ft. lbs.) + 180°
Front fastening screws: M14 x 145
Middle fastening screws: M14 x 95
Rear fastening screws: M14 x 1 10
14. Secure transmission cross member with new screws (M10 x 75) -A- . Tightening torque: 50 Nm (37 ft. lbs.) + 90°
15. Release the lateral supports on the wheel hubs.
16. Lower the lift truck slowly and remove.
17. Connect the electrical plugs -1, 2 and 3- to the transmission.
Plugs on the transfer box -1, 2 and 3-
18. Mount the selector cable. To do this, press on the ball joint and clip in tab washer.
Note:
^ In vehicles with an off road stabilizer, the electric lead must also be connected to the stabilizer.
^ In addition, the two hydraulic lines (near the steering gear) must be screwed on.
Hydraulic lines
19. Push the servo oil line onto the oil cooler and mount the spring band clamp.
Note: In the case of vehicles with Servotronic, the electronic plugs on the steering gear must also be connected.
20. Slide the steering column onto the steering gear and tighten new screw. Tightening torque: 35 Nm (26 ft. lbs.) + 90°
21. Fit the heat shield on the steering gear by means of 2 fastening screws. Tightening torque: 10 Nm (7.5 ft. lbs.).
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 plug must engage audibly.
25. Connect the ATF lines to the cooler. Remove the sealing plugs and mount the top line first. Subsequently, mount the bottom line and tighten the fastening screws (M6 x 20) to 10 Nm (7.5 ft. lbs.).
26. Mount the ground point of the generator on the right side member. Tightening torque: 23 Nm (17 ft. lbs.)
27. Tighten the catalytic converter fastening on the body. Tightening torque: 23 Nm (17 ft. lbs.)
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. Tighten the fastening screws in the middle section and at the front to 23 Nm (17 ft. lbs.).
32. Tighten the two fastening screws at both the left and right of the rear silencer. Tightening torque: 23 Nm (17 ft. lbs.)
33. Connect the exhaust system. Slide the new exhaust clamp backwards from the catalytic converter and over the exhaust pipes. The screw connection points must point vertically downwards. Exhaust clamp tightening torque: 60 Nm (44 ft. lbs.).
34. Install the front cross-member under the radiator. Tighten the 4 fastening screws (M8 x 25) to 23 Nm (17 ft. lbs.).
35. Screw the front spoiler to the transverse strut.
36. 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 beam adjustment sensor.
37. Tighten the brake lines on the left and right in the wheel wells.
38. Fit the electrical connections of the spring struts. To do this, connect cable -1- and then fasten holders -2 and 3- .
39. 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.
40. Fit the three new fastening screws (M10 x 37) on the left and right spring struts from above. Tightening torque: 50 Nm (37 ft. lbs.) + 90°.
41. Connect the four oxygen sensor connectors at the radiator tank splash panel.
42. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine over the pins. Tightening torques: 23 Nm (17 ft. lbs.)
43. Connect the servo line to the expansion tank and mount the spring band clamp. Then fill the tank with Pentosin.
44. On the radiator tank splash panel, tighten carbon canister wire -2- and fuel line -1- to 35 Nm (26 ft. lbs.). Then attach the vacuum line -3- .
45. Connect the vacuum line to the right spring dome and mount the spring band clamp. Then mount the 2 lines on the coolant expansion tank and secure with spring band clamps.
46. Lay the engine wiring harness into the radiator tank. Fit the rubber sleeve into the middle opening. Then guide the control unit plug to the right. Connect the control unit, plug and ground point. Ground point tightening torque: 10 Nm (7.5 ft. lbs.).
47. Plug in the 4 plugs (red, brown, white and black) in the left-hand central electrical system box. Then mount the cover using four Torx screws.
48. Check whether the wiring harness is laid correctly. Close all fastening clips.
49. Mount the plenum chamber cover. Do not forget the electric plug. Mount the four bayonet screws -A- .
50. Fit the drive belt and check that it is positioned correctly. Then remove the locking screw.
51. Connect the upper right coolant connection piece to the radiator. The connection piece must engage audibly.
52. Insert the air filter element.
53. Insert the air cleaners into the housing and slide on the cover from the top downwards. Then close the two respective metal clamps.
54. Push the air line on the air cleaner cover.
55. Fit the intake manifold. To do this, push the intake manifold onto the throttle body and fit the vacuum line at the same time. Then attach the other end to the lid of the air cleaner housing.
56. Attach the hose clamp, the electric connector on the mass air-flow meter and the 2 fastening pins on the air cleaner housing.
57. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must be felt to engage.
58. Bleed and fill the cooling circuit.
59. Bleed the brake system.
60. Connect battery.
61. Install the windscreen wipers. Switch on the wiper motor briefly. Then mount the wiper arms. Tightening torque: 32 Nm (24 ft. lbs.).
62. Fit the engine compartment cover.
63. Check ATF level.
64. Bleed power-assisted steering.
65. Bleed off road stabilizer.
66. Mount front wheels. Tightening torque: 160 Nm (118 ft. lbs.).
67. Perform suspension alignment.
68. Install underride guard.
69. Install seat. Tightening torque: 45 Nm (33 ft. lbs.).
Torques