100127 Removing Engine From Transmission and Mounting Engine on Transmission
WM 100127 Removing engine from transmission and mounting engine on transmission
Tools
Preliminary work
Preliminary work for removing engine from transmission and mounting engine on transmission
1. Engine removed. Engine/transmission unit is on the lifting platform. -> 100119 Removing and installing engine - section on "Removing" 100119 Removing and installing engine
2. Detach the design cover from the engine. -> 108319 Removing and installing engine cover (design cover) - section on "Removing" 108319 Removing and installing engine cover (design cover).
Removing engine from transmission
Information
- When removing the engine, ensure that the torque converter in the automatic transmission does not slip out of the transmission.
- Keep the torque converter pressed in position using a screwdriver when removing the engine.
Information
Some of the repair illustrations show only one side of the vehicle. Naturally, some steps also have to be performed on the opposite side of the vehicle as well. These must be carried out as a mirror image of the steps shown.
Information
- The pictures shown in this document may differ from the original.
- However, this does not affect the validity and relevance of the pictures.
Engine/transmission assembly
1. Detach holder -1- for ATF lines at the front of the engine.
Holder for ATF lines at front of engine
2. Detach holder -1- for ATF lines at the rear of the engine.
Holder for ATF lines at rear of engine
3. Loosen clamps -1- for the coolant hoses -2- on the left of the transmission.
Pull off coolant hoses.
Coolant hoses on left
4. Unscrew fastening screws -1- for coolant line holder -2- , bend holder to one side.
Holder for coolant lines
5. Unclip the wire harness -1- for the oxygen sensors on the left cylinder head cover out of the holder -2-.
Wire harness for left oxygen sensor
6. Unclip the wire harness -1- for the oxygen sensors on the right out of the holders -2-.
Wire harness for right oxygen sensor
7. Spray the fastening screws on the primary catalytic converter with penetrating oil and leave to take effect.
Loosen the fastening screws -1- on the catalytic converter.
Primary catalytic converters
8. Loosen the fastening screws -1- for the holders -2- of the left and right primary catalytic converters -3-.
Holder for primary catalytic converter
9. Loosen the fastening screws -1- on the left and right for the rear holders -2- of the catalytic converters on the transmission.
Holder for catalytic converters
10. Remove the catalytic converters and set them aside.
11. Remove the front cardan shaft. -> 390219 Removing and installing front cardan shaft - section on "Removing" 390219 Removing and Installing Front Cardan Shaft
12. Release the electric plug connection -1- of the crankshaft pulse sender at the bottom of the transmission -a- and pull it off -A-.
Plug connection for crankshaft pulse sender
Loosen the tie-wrap at the coolant line holder on the left if necessary.
13. Unclip the hose -1- for the transmission vent from the holder -2-.
Transmission vent hose
14. Loosen the clamp -1- for the coolant hose -2- to the ATF heat exchanger on the right and pull off the hose from the connection piece.
Right coolant line
15. Pull off vacuum hose -1- for the vacuum supply at the T-piece -2-.
Unclip the vacuum line -3- from the holder -4-.
Vacuum supply
16. Remove plug -1- used to seal the converter assembly opening.
Removing plug used to seal converter assembly opening
17. Remove converter screws. Follow the steps below to do this. -> 325019 Removing and installing torque converter - section on "Removing" Service and Repair
18. Turn crankshaft clockwise using special tool socket-wrench insert 97140.
19. Insert special tool fixing pins 95950 into the front bore on the converter bell housing -arrow- and hold upwards with light pressure until it engages when the crankshaft is turned.
Disconnecting converter screws
20. Position special tool bit insert 96880 on converter screw through opening in the engine block, connect bit snap-on head and special tool insert 96870 one after the other.
Opening for converter screws
21. Remove special tool locating pins 95950 before loosening the converter screws.
22. Unscrew converter screw and twist out.
23. Complete the steps described above for the other five screws.
24. Secure engine to the lifting tackle and to the workshop crane => Securing engine to workshop crane.
Securing engine to workshop crane
25. Secure the transmission with a suitable tool, e.g. a wooden block, to prevent it from tipping away.
Wooden block placed underneath
26. Lift the engine/transmission unit until the four screws on the two engine mountings can be removed. -> 103519 Removing and installing engine mounting - section on "Removing" Service and Repair
27. Slowly lower the engine/transmission unit onto the wooden block. The engine is still suspended securely on the workshop crane.
28. Loosen the fastening screws -1- for the transmission to the engine.
Loosening transmission from engine
29. Remove engine from transmission. Press the torque converter off the drive plate with a screwdriver if necessary.
30. Remove the engine from the transmission at the lifting crane.
Transmission without engine on lifting platform
Mounting engine on transmission
WARNING
Objects or loads falling down
- Risk of squashing or crushing
-> Secure components to prevent them from falling down.
Information
- Screws which are tightened with a torque angle must be replaced with new ones.
Information
- A second fitter is required.
- Replace converter screws.
Information
- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
1. Fix engine to the crankshaft with special tool fixing pins 9595.
Disconnecting the crankshaft
2. Insert special tool centering pin 9689 in converter.
Torque converter centering pin
3. Lift the engine with the workshop crane and move it into the installation position with respect to the transmission.
4. Put engine and transmission together.
5. The dowel sleeves on the engine must slip perfectly into the bores on the transmission bell housing.
6. Fit the transmission screws -1- with the holders -2- for the primary catalytic converters. -> 373519 Removing and installing transmission - section on "Installing" 373519 Removing and Installing Transmission
Fitting transmission screws
7. Remove special tool centering pin 9689 and fit torque converter screws. For tightening torques refer to -> 373527 Removing and mounting transmission - section on "Mounting" 373527 Removing and mounting transmission, -> 325019 Removing and installing torque converter - section on "Installing" Service and Repair
8. Carefully lift the engine and transmission assembly with the workshop crane.
9. Place ATF lines on the engine and fit the holder -1- to the front of the engine using a fastening nut.
Holder for ATF lines at front of engine
10. Fit engine mounting. -> 103519 Removing and installing engine mounting - section on "Installing" Service and Repair
10.1. Remove wooden block under transmission.
10.2. Carefully lower the engine and transmission assembly, making sure the engine mounting is seated correctly in the engine carrier.
10.3. Fit engine mounting. -> 103019 Removing and installing engine carrier - section on "Installing" 103019 Removing and installing engine carrier
11. Remove workshop crane from the engine.
12. Screw in new converter screws.
13. Place screw on special tool bit insert 9688 and screw in screw.
Opening for converter screw on engine
14. Position bit snap-on head and special tool insert 9687 and screw in screw, but do not tighten.
15. Turn crankshaft clockwise with special tool socket wrench insert 9714.
16. Insert special tool locating pins 9595 into the front bore on the converter bell housing -arrow- and hold in place with light pressure until it engages when the crankshaft is turned. This sets the position for the next screw.
Disconnecting converter screws
17. Complete the steps described above for the other five screws.
18. Remove special tool fixing pins 9595 before tightening the converter screws to the specified torque. For torque see -> 373519 Removing and installing transmission 373519 Removing and Installing Transmission
19. Insert plug for converter assembly opening. To do this, moisten the groove on the plug with water.
Plug used to seal converter opening
20. Starting at the cut-out in the engine block -1- , press in the stopper all the way round from position -2-3-.
Plug
21. Check the position of the plug -2- using an inspection mirror -1-. When doing this, make sure that the sealing lip -3- makes contact all the way round.
Installation position of plug
22. Push the vacuum hose -1- onto the T-piece -2-.
Vacuum supply
Clip vacuum line -3- into the holder -4-.
23. Connect the coolant hose -2- for the ATF heat exchanger on the right to the connection piece and fit the clamp -1-.
Right coolant line
24. Clip the hose -1- for the transmission vent into the holder -2-.
Transmission vent hose
25. Connect the electric plug connection -1- of the crankshaft pulse sender at the bottom of the transmission -A- and lock it -a-.
Secure the wire harness with a tie-wrap if necessary.
Plug connection for crankshaft pulse sender
26. Fit the front cardan shaft. -> 390219 Removing and installing front cardan shaft - section on "Installing" 390219 Removing and Installing Front Cardan Shaft
27. Place the catalytic converters in position on the engine and transmission assembly.
27.1. Position the fastening nuts -1- of the primary catalytic converters and fit them.
Primary catalytic converters
27.2. Position the primary catalytic converters -3- at the gear supports -2- and fit the fastening screw -1-.
Holder for primary catalytic converter
27.3. Fit the fastening screws -1- of the rear catalytic converters to the holders -2- at the transmission.
Holder for catalytic converters
28. Clip the wire harness -1- for the oxygen sensor on the right into the holders -2- on the engine.
Wire harness for right oxygen sensor
29. Clip the wire harness -1- for the oxygen sensor on the left at the cylinder head cover into the holder -2-.
Wire harness for left oxygen sensor
30. Place the holder -2- for the coolant lines in position on the transmission and fit the fastening screw -1-.
Holder for coolant lines
31. Connect the coolant hoses -2- on the left of the transmission and fit the clamps -1-.
Coolant hoses on left
32. Position holder for ATF line on the rear of the engine and fit fastening screw -1-.
Holder for ATF lines at rear of engine
Subsequent work
Subsequent work for removing engine from transmission and mounting engine on transmission
1. Fit the design cover on the engine. -> 108319 Removing and installing engine cover (design cover) - section on "Installing" 108319 Removing and installing engine cover (design cover).
2. Install engine. -> 100119 Removing and installing engine - section on "Installing" 100119 Removing and installing engine