Part 2
WM 100119 Removing and installing engine
Installing engine
Information
- Due to currently correct tightening specifications, the screw specifications can be found in the corresponding repair descriptions for the assemblies chassis, transmission, electrics, etc.
Special equipment-specific features are described in the notes.
Tool setup - Master Gear unit elevating platform WE 1206 with suitable setup kit.
Lifting platform
1. Slide the lifting platform -1- with the engine/transmission assembly to the marked positions -A- on the workshop floor.
Position of lifting platform
2. Raise the body to a comfortable working height with the platform lift.
3. Raise the engine/transmission unit into the body using the lifting platform => Guiding engine/transmission unit into the body with the lifting platform. Make sure there is sufficient clearance. The freely-suspended lines (e.g. PDCC) must be routed in such a way that they do not go back into the installation position (the lines must not be trapped). The insertion guides -4- on the lifting platform must fit into the holes in the body. When doing this, use the markings made during removal as a positioning guide.
Lifting platform
Guiding engine/transmission unit into the body with the lifting platform
4. Then insert the engine fully up into the engine compartment. => Inserting engine completely When doing this, use the markings made during removal as a positioning guide.
Inserting engine completely
5. Tighten the six new front-axle carrier and engine carrier screws => Fastening screws for front-axle carrier and engine carrier. For details see -> 400619 Removing and installing front-axle carrier - section on "Installing" 400619 Removing and installing front-axle carrier.
Fastening screws for front-axle carrier and engine carrier
6. Install transmission cross member. For details see -> 396519 Removing and installing transfer gear - section on "Installing" Service and Repair -A-.
Fastening screws for transmission cross member
7. Loosen the lateral supports on the wheel hubs. => Support on wheel hub
Support on wheel hub
8. Lower the lifting platform slowly and remove it.
9. Plug in electric plug connections -1, 2- at the bottom of the transfer gear -A, B- and lock them -a, b-
Plug connections for transfer gear at the bottom
10. Plug in electric plug connections -1, 2- at the right of the transfer gear -A, B- and lock them -a, b-.
Plug connections for transfer gear at the right
11. Fit heat shield on the right of the transmission. To do this, screw in the fastening screws -arrows-. => Tightening torque: 10 Nm (7.5 ftlb.)
Heat shield
12. Fit shift cable -3- on automatic transmission -4-. -> 371519 Removing and installing selector lever cable - section on "Installing"
Shift cable on automatic transmission
12.1. Clip in shift cable -3- at the ball joint -1-.
12.2. Fit the fastening screws -2-.
13. Fit the coolant line -1- from the air-conditioning compressor to the condenser -2-. -> 874319 Removing and installing compressor/condenser line - section on "Installing" 874319 Removing and installing air-conditioning compressor/condenser line
Use a new sealing ring.
Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.
Line from air-conditioning compressor to condenser
13.1. Fit the coolant line -1- on the condenser -2- and screw in the fastening screw -3-.
14. Position front part of refrigerant line -2- from the compressor to the evaporator at the longitudinal member -3- at the left. -> 874419 Removing and installing condenser/evaporator line - section on "Installing" 874419 Removing and installing condenser/evaporator line
Use a new sealing ring.
Make sure that the guide pin at the connection point fits into the mounting for the refrigerant line.
Front left refrigerant line
Screw in fastening screw -1-.
15. Slide hose onto the hydraulic line -2- in the front left wheel housing and position the clamp -1-.
Front left hydraulic line
16. Attach hoses -2- to the coolant lines in the engine compartment at the rear left and position the clamps -1-.
Coolant lines in front left wheel housing
17. Fit the steering column -2- on the steering gear -3-. -> 481519 Removing and installing steering column - section on "Installing" 481519 Removing and installing steering column
Installing steering column
17.1. Fit the steering column -2- from above -arrow- onto the steering gear -3- ( -A- ).
17.2. Fit clamping screw. -> 4X00IN Tightening torques for steering [1][2]Specifications
Always use a new clamping screw.
18. Fit ATF lines at the thermostat. -> 386219 Removing and installing line for ATF cooling - section on "Installing"
ATF lines from thermostat to transmission
18.1. Insert ATF lines -3- into the thermostat -4-.
18.2. Place holder -2- for ATF lines -3- to the ATF thermostat -4- in position.
Ensure that the lines are seated correctly.
18.3. Fit the fastening screw -1-.
19. Fit the cardan shaft -> 393519 Removing and installing rear cardan shaft 393519 Removing and installing rear cardan shaft.
20. Push new exhaust clamps (clamping sleeves) -3- onto the exhaust pipes. The threaded joint must be pointing downwards.
Tighten fastening screws. -> 260119 Removing and installing exhaust system - section on "Installing" Service and Repair
Fitting clamps
Information
- For vehicles with Servotronic, the electric connectors on the steering gear must also be connected.
21. Fit electric connector on the steering gear (Servotronic only). -arrow-
Servotronic cable plug
22. Slide the coolant supply and return lines onto the radiator. To do this, press the top hose on the radiator flange until you feel it engage -1-. Slide on bottom hose -2-. Then fit the spring band clamp.
Connect the small breather hose.
Coolant hoses
23. Mount the ground point of the generator on the right side member. => Tightening torque: 20 Nm (15 ftlb.)
Ground point of the generator to the right side member
Information
The slightly different illustrations between V8 and V6 show essentially the same actions.
24. Fit the wheel bearing housing on the ball joint of the upper trailing arm. -> 401519 Removing and installing upper trailing arm (steel springs) - section on "Installing" 401519 Removing and installing upper trailing arm (steel springs)
25. Raise the axle support -1- as far as required using a suitable jack -4- until the fastening screw -2- slides easily through the spring strut -3- and axle support.
Spring strut threaded joint
26. Fit the fastening screw -2- for the spring strut -3- and trailing arm -2-. -> 4X00IN Tightening torques for front axle - section on "Installing" 4X00IN Tightening torques for front axle
27. Plug in electric plug connection -1- for the speed sensor on the wheel bearing housing -A- and lock it -a-.
Electric plug connection for speed sensor (shown as an example)
28. Position and fit the brake caliper on the brake disc at the wheel bearing housing. -> 473919 Removing and installing front brake caliper - section on "Installing" 473919 Removing and installing front brake calliper 473919 Removing and installing front brake calliper (PCCB)
29. Fit the holders -1, 2- for the hydraulic lines on the wheel bearing housing -3-.
Mounting for hydraulic lines
30. Fit the connecting link -2- on the anti-roll bar -3- and screw in the fastening screw -1-.
Connecting link for anti-roll bar
31. Lower the vehicle halfway.
32. Connect the four oxygen sensor connectors at the radiator tank splash panel. -1, 2, 3 and 4-
Oxygen sensor connector on the plenum panel splash panel
33. Mount B+ transfer point on left spring dome. To do this, connect the two positive cables from the engine using the pins. Clip in cable on the bulkhead. -A and B- => Tightening torque: 23 Nm (17 ftlb.)
B+ transfer point on left spring dome
34. Fit the hoses -3, 4- to reservoirs.
Fill the hydraulic fluid reservoir -1- and the PDCC reservoir -2- , if necessary, to the correct fluid level.
Hoses for hydraulic reservoir
35. Fit fuel line -1- and tank vent line from the carbon canister -2- to the plenum panel splash panel. Clip in tank vent line at the plenum panel. => Tightening torque: 35 Nm (26 ftlb.)
Tank vent and fuel line
36. Slide the coolant line -4- at the bottom onto the coolant reservoir -2- and lock the clamp -3-.
Coolant lines at the reservoir
37. Fit the two coolant lines and the vacuum line on the right side of the engine compartment. -1 to 3- Simply press on the vacuum line (hold line securely below the connection).
Wiring
38. Route the engine wire harness -1- in the plenum panel and clip it into the retaining clips -2-.
Engine wire harness in plenum panel
39. Plug in and lock the electric plug connections -1- for the engine wire harness in the relay box.
Plug connections in relay box
40. Close the relay box. -> 970909 Loosening and securing main wire harness in engine compartment at the left 970909 Loosening and securing main wire harness in engine compartment at the left
41. Attach tank vent lines and lock the clamp -2-.
42. Fit the ground strap -2- in the plenum panel at the body and screw on the fastening nut -1-.
Secure the ground strap to the engine wire harness with tie-wraps -3- if necessary.
Ground point on body
43. Plug in electric plug connection -1- on the engine control unit -2- ( -A- ) and lock it -a-.
Plug connection for engine control unit
44. Fit air cleaner housing cover and filter element.
45. Push the air line on the air cleaner cover.
Air line on air cleaner cover
Subsequent work
1. On vehicles with manual transmission, work on peripheral units must be performed as described in -> 343519 Removing and installing transmission - section on "Installing" Removal and Replacement.
2. Install intake pipe. -> 243519 Removing and installing air box for throttle housing on DFI engines (intake pipes upstream of throttle valve) - section on "Installing" Service and Repair
3. Install cover for plenum panel. -> 664419 Removing and installing cowl panel cover - section on "Installing" Service and Repair
4. Fit pneumatic springs for bonnet -> 553119 Removing and installing front gas spring Service and Repair. Fit rubber seal for engine compartment at the same time.
5. Fill and bleed the cooling system. -> 193817 Draining and topping up with coolant (includes bleeding) - section on "Topping up" Service and Repair
6. Connect the battery. => Work instructions after disconnecting the battery
7. Fit engine compartment trim panels. -> 700219 Removing and installing front trim (engine compartment) - section on "Installing"
8. Check ATF level. => Test and assembly work on power steering
9. Bleed the power steering or PDCC. => Test and assembly work on power steering
10. Install front wheel housing liners. -> 505619 Removing and installing front wheel housing liner - section on "Installing" Service and Repair
11. Install engine guard with transverse strut.
12. Mount front wheels. -> 440519 Removing and installing wheel - section on "Installing" Removal and Replacement
13. Perform suspension alignment. => Suspension alignment, complete
14. 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.
15. Read out DME fault memory and compare with the log you printed prior to removal.
16. Check fluid levels.