100431 Re-fitting reconditioned engine (replacing engine)
WM 100431 Re-fitting reconditioned engine (replacing engine)
Preliminary work
1. Remove engine -> 100119 Removing and installing engine - section on "Removing" 100119 Removing and installing engine.
2. Remove engine from transmission -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing Engine From Transmission and Mounting Engine on Transmission.
Removing engine from engine carrier (lifting engine from elevating platform)
1. Also support engine on the assembly table at the front.
2. For all-wheel drive: Loosen front drive shafts on the transmission side -> 404119 Removing and installing front drive shaft - section on "Removing" 404119 Removing and installing front drive shaft.
3. Disconnect lower torque support at the engine side -> 103719 Removing and installing torque support - section on "Removing" 103719 Removing and installing torque support.
3.1. Replace fastening screw.
4. Disconnect engine mounting on both sides from underneath -> 103519 Removing and installing engine mounting - section on "Removing" Service and Repair.
5. Disconnect front PDCC expansion hose.
Disconnecting expansion hose
5.1. Open the clamp.
5.2. Disconnect expansion hose.
6. Disconnect power steering line on the steering gear -> 489419 Removing and installing hose for power steering - section on "Removing" Removal and Replacement.
7. Detach design cover over cylinder block 1-4 in order to expose the eyelets -> 108319 Removing and installing engine cover (design cover) Service and Repair.
8. Lift engine off engine carrier.
8.1. Carefully lift the engine initially using a workshop crane For details, see -> 1001IN Lifting the engine (workshop crane) 1001IN Lifting the engine (workshop crane)
8.2. Make sure that the engine can be lifted up further without squashing or tilting components.
8.3. Secure loose components and auxiliary units.
8.4. Raise the engine.
9. Move elevating platform out from under the engine.
Re-fitting engine
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. Re-fit turbo intake pipes on both sides.
1.1. For cylinder bank 5 to 8 with positive crankcase ventilation.
2. Re-fit turbo pressure line on both sides -> 214119 Removing and installing pressure pipe.
3. Re-fit coolant hose holder on timing-case cover.
3.1. Replace fastening screw.
4. Re-fit drive belt -> 137819 Removing and installing drive belt 137819 Removing and installing drive belt.
5. Re-fit drive-belt deflection roller.
6. Re-fit air-conditioning compressor -> 873419 Removing and installing air-conditioning compressor.
7. Re-fit hydraulic pump/tandem pump -> 489855 Replacing hydraulic pump 489855 Replacing hydraulic pump (PDCC).
8. Re-fit design cover -> 108319 Removing and installing engine cover (design cover) Service and Repair.
9. Re-fit secondary-air pump as required -> 266519 Removing and installing secondary-air pump with bracket Service and Repair.
10. Re-fit entire secondary-air system including switching valves as required -> 267519 Removing and installing secondary-air valve.
11. Re-fit Y-shaped pipe with positive crankcase ventilation line.
12. Re-fit ground cable.
13. Re-fit crash panel for high-pressure pump.
14. Re-fit coolant hoses and pipes.
15. Re-fit vacuum line for flap exhaust system as required.
16. Re-fit flywheel -> 136019 Removing and installing flywheel Removal and Replacement.
Subsequent work
Mounting engine on engine carrier (lifting engine onto elevating platform)
The engine is mounted on the mounting bracket in the opposite sequence to removal.
Subsequent work
1. Re-fit transmission -> 100127 Removing engine from transmission and mounting engine on transmission 100127 Removing Engine From Transmission and Mounting Engine on Transmission.
2. Install engine -> 100119 Removing and installing engine - section on "Installing" 100119 Removing and installing engine.