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Remove/install engine (version 1) - RA0100104A300X(01-0300)

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Preceding work:

Warning instructions when hood open (01-0085) 

Bottom engine compartment panel removed (Maintenance)

Air cleaner removed (REMOVING AND INSTALLING AIR CLEANER - AR09.10-P-1050D )

Radiator removed (20-4200)

Viscous fan coupling removed (20-3120)

Operation no. of operation texts and work units or standard texts and flat rates:

A. Models 124, 129, 140 

Fig 1: Identifying Engine Remove/Install Components
G04676707Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Engine with transmission remove, install.
Ground cable at battery disconnect, connect, encode radio, model 140 normalize power windows.
Coolant drain at crankcase.
If AC fitted attach guard plate to condenser.
Air-to-oil cooler pipes (1) at air-to-oil cooler disconnect, connect (step 3).
If AC fitted: take off poly V-belt, fit on (13-3200) .
Power steering pump extract oil from reservoir, adjust oil to correct level (step 5).
AC compressor (4) remove with piping connected, place to the side, fit on.
Oil pipes of power steering pump, automatic transmission take off, seal and fit on (steps 7-8).
Fuel pipes take off, seal, open fuel filler cap briefly first of all, fit on (step 9).
Bowden cable (accelerator control) take off, fit on (30-1010 , step 10).
Heating water return pipe detach, attach.
Component compartment cover remove, install model 140 (step 14).
Right cable duct remove, install model 140 (step 14).
Electrical connections disconnect, connect (steps 15 to 21).
Electrical connections, starter disconnect, connect (steps 23, 24).
Vacuum pipes for brake pressure regulator etc. detach, attach.
Exhaust system remove, install (49-0045 , 49-0170 ).
Flexible disc (5) of transmission (6) detach, attach, replace self-locking nuts step 25).
Clamping nut and intermediate bearing fixture slacken, tighten (steps 26, 27).
Shift rods at transmission detach, attach (step 28).
If manual transmission fitted: unbolt hydraulic pipes for clutch, bolt on (step 29).
If automatic transmission fitted: disconnect starter lockout switch, transmission overload protection, electric wiring, connect (steps 30, 32, 33, 34).
Engine hoist attach to lifting lugs, detach (step 35).
Transmission support.
Rear engine support (7) without engine mounts remove, install (step 37).
Exhaust bracket at transmission unbolt, bolt on (step 38).
Front engine mounts (8), left and right unbolt from below, bolt on (step 39).
Guard plate at component compartment wall insert, take off.
Engine raise with engine hoist, lower (step 41).
Front and rear engine mounts examine.
Coolant, oil and fuel hoses examine.
If automatic transmission fitted adjust Bowden cable for control pressure.
Oil drain plugs check tightening torque.
Oil level in engine and transmission adjust to correct level (18-0020) .
Coolant pour in, check anticorrosion/antifreeze agent and adjust to correct ratio (20-0100) .
Idle speed check, adjust.
Fault memory read, erase (step 52).
NOTE: Faults stored in the fault memories must be rectified after completing the work and erased.

See Diagnosis Manual Volume 2:
Index 0: Connecting and using test equipment.
Leak tightness check after test run of engine.
TIGHTENING TORQUES IN NM

Oil pipes to air-to-oil cooler 30
Oil pipes to air-to-oil cooler 30
Knock sensors to crankcase(1) 20
(1) Bolt head contact surface and thread oiled

Special tools 

Fig 2: Identifying Special Tools (001 589 66 21 00)
G04676708Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Fig 3: Identifying Special Tools (000 589 40 37 00)
G04676709Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
COMMERCIALLY AVAILABLE TOOLS AND TESTERS

Removal device components model 3188 (lifting capacity 500 kg) e.g. Wilbar GmbH & Co KG
Herder Str.
42895 Remscheid
SHOP-MADE TOOLS

Guard plate for radiator /condenser sizes approx. 400x680x1 mm
Metal plate for component compartment wall sizes approx. 320x380x1 mm
NOTE: IMPORTANT In the case of engine damage involving damage to the pistons, valves etc., parts may have got in as far as the catalytic converter, or pre-catalytic converter.

When replacing the engine, it is essential to remove such parts otherwise they will be pulsed back into the cylinders as a result of the gas vibrations in the exhaust system and may once again cause engine damage.

In addition, these parts may cause mechanical damage to the catalytic converter.

It is therefore essential to remove any foreign bodies in the exhaust system in the case of such engine damage.

Catalytic converters which have been damaged must be replaced.

Engine 104.990 in model 140 

When replacing the crankcase or installing a reconditioned engine, the matched ignition control module (DI) should be used, see 01-1000 .

Removing and installing engine with transmission.

  1. Disconnect ground cable at battery.

    Installation note 

    Encode radio, model 140 normalize power windows.

  2. If AC fitted: attach guard plate to condenser of AC system.
  3. Unbolt air-to-oil cooler pipes at air-to-oil cooler (arrows)
    Fig 4: Locating Unbolt Air-To-Oil Cooler Pipes
    G04676710Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Model 140 

    • Unbolt oil cooler pipes at body (arrows).
  4. If AC fitted: remove poly V-belt (13-3420) .

    Model 140

    Fig 5: Locating Unbolt Oil Cooler Pipes And Body
    G04676711Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  5. Extract oil from the reservoir of the power steering pump with the priming pump for extracting oil.

    Installation note 

    Check fluid level of power steering system. Fill up power steering with the specified fluid. Top up fluid to the marking with the engine running. Turn steering several times from full left to full right lock. When fluid is at normal operating temperature, it must extend to about 20 mm below the edge of the reservoir; when fluid is cold to 6-8 mm below the marking.

    Fig 6: Identifying Top Up Fluid
    G04676712Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  6. Detach AC compressor of air conditioning system from the engine.

    Unscrew bolts (35) and nuts (for attaching pipe assy) ; attach AC compressor to the side at the bottom of the engine compartment with the pipes connected.

    Fig 7: Identifying Unscrew Bolts And Nuts
    G04676713Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  7. Unbolt suction and pressure oil pipes at power steering pump and tandem high pressure pump, respectively (arrows).

    Installation note for tandem pump 

    Bleed pressure oil pump (level section) of tandem pump.

    Fig 8: Identifying Unbolt Suction And Pressure Oil Pipes
    G04676714Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  8. Unbolt delivery pipe of level pump (1), unscrew M8 bolts (3) of metal bracket (2) and press pressure pipe out of the metal brackets (arrows).
    Fig 9: Identifying Unbolt Delivery Pipe Of Level Pump And Metal Bracket
    G04676715Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  9. Briefly open filler cap in the fuel tank to release the pressure.

    Unbolt fuel pipes (arrow) and seal with special tool 000 589 40 37 00. Counter-hold the connection fitting (1) when slackening the fuel pipe.

    Fig 10: Identifying Unbolt Fuel Pipes And Seal (Engine 104.98, Models 124, 129)
    G04676716Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
    Fig 11: Identifying Unbolt Fuel Pipes And Seal (Engine 104.99)
    G04676717Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  10. Detach Bowden cable (30) from accelerator control lever (9). Compress plastic clip (28) and pull out Bowden cable.

    Installation note 

    Adjusting Bowden cable (30-1010 ).

    Fig 12: Identifying Bowden Cable, Plastic Clip And Accelerator Control Lever (Engine 104.98)
    G04676718Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  11. Detach Bowden cable (30) from accelerator control lever (9). Compress plastic clip (28) and pull out Bowden cable.

    Installation note 

    Adjusting Bowden cable.

    Fig 13: Identifying Bowden Cable, Plastic Clip And Accelerator Control Lever (Engine 104.99)
    G04676719Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  12. Detach heater hoses and vacuum pipes in the engine compartment. If automatic transmission fitted, pull off vacuum pipe at 2-way valve.

    Models 124, 129 

  13. Detach connector from the oil level gauge and from the oil pressure sensor.

    Slacken all cable straps of the engine wiring harness. Detach all connectors along the engine wiring harness.

    Remove engine wiring harness

    Model 140 

  14. Remove component compartment cover (3), open cable duct (1) and remove right-hand side.
    Fig 14: Identifying Cable Duct And Component Compartment Cover
    G04676720Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  15. Unplug connectors (items X26/17 and M16/1x1) of the engine wiring harnesses. Press ratchet (arrow) and turn to release the connector (16/1x1).
  16. Place engine wiring harnesses on the engine.
    Fig 15: Unplugging Connectors
    G04676721Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  17. At the ignition control module, unplug crankshaft position sensor connector (L5), LH control module connector (B), knock sensors connector (A16) and detach vacuum pipe (arrow).
  18. Detach suction pipe of the evaporative emission control system from the connector on the left-hand wheelhouse.
    Fig 16: Unplugging Crankshaft Position Sensor Connector (L5)
    G04676722Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Model 124 

  19. Detach cable connector terminal TD (arrow) next to diagnostic socket (X11).

    Models 124, 129, 140 

  20. Unbolt diagnostic socket (X11), detach cable from TD sensor on rear of diagnostic socket.
    Fig 17: Identifying Diagnostic Socket Cable Connector Terminal TD
    G04676723Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

    Models 124, 129 

  21. Disconnect wiring (327) at the generator.
    Fig 18: Identifying Generator Wiring
    G04676724Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  22. Remove exhaust system (40-0045 , 49-0170 ).
  23. Remove heat shields above front and underfloor catalytic converter (model 140 only).

    Model 140 

  24. Unbolt starter wiring harness X27 and terminal 30 at screw connection X4/10 on front right of firewall from below.
    Fig 19: Identifying Unbolt Starter Wiring Harness X27
    G04676725Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  25. Detach propeller shaft by unscrewing bolts (arrows).
    NOTE: The propeller shaft is balanced together with the flexible joint.
    Fig 20: Identifying Propeller Shaft Unscrewing Bolts
    G04676726Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  26. Slacken bolts for propeller shaft intermediate bearing but do not remove.
  27. Slacken clamping nut (waf 41/46) of propeller shaft. Push back propeller shaft as far as possible. Tightening torque 30-40 Nm.
    Fig 21: Identifying Slacken Nut Of Propeller Shaft
    G04676727Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  28. If manual transmission fitted: take shift rods off the transmission shift levers after pressing off the clip locks.
  29. If manual transmission fitted: separate hydraulic pipe (arrow) to the slave cylinder at the hose connection.

    Seal pipes with dummy plugs or extract fluid from the rear chamber of the combined expansion reservoir.

    Fig 22: Separating Hydraulic Pipe To Slave Cylinder Hose Connection
    G04676728Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  30. If automatic transmission fitted: slacken cable strap (23) and unscrew cable (6) at the kickdown solenoid valve (61) or pull off. Unscrew fastening bolt for the pulse generator (arrow) and pull out the pulse generator.
  31. Unbolt ground cable at transmission.
    Fig 23: Identifying Slacken Cable Strap, Unscrew Cable And Solenoid Valve
    G04676729Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  32. Remove connector for starter lockout switch (8).

    IMPORTANT The connector for the starter lockout switch is secured by a locking element (white plastic ring, arrow).

    Before pressing off the connector, the locking element must be turned up (direction of arrow).

    Detach shift rod (9) in the range selector lever.

    Fig 24: Identifying Starter Lockout Switch Connector
    G04676730Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  33. Use two screwdrivers to carefully press off the connector (8) at the cable outlet and at the tab.
    Fig 25: Identifying Connector And Screwdrivers
    G04676731Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  34. Unscrew connector for transmission overload protection (arrow).
    Fig 26: Identifying Transmission Overload Protection For Unscrew Connector
    G04676732Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  35. Attach engine hoist to the lifting lugs of the engine.

    Adjust engine hoist so that the engine can be raised horizontally.

  36. Support transmission in trolley jack or in inspection pit lift.
  37. Unbolt rear engine support without engine mounts. Unscrew bolts item 1.
  38. Unscrew securing bolts (2) of the exhaust bracket (3) at the transmission.
    Fig 27: Identifying Exhaust Bracket And Unscrew Securing Bolts
    G04676733Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  39. Unscrew bolts (a) at the left and right front engine mounts from below.
    Fig 28: Identifying Left And Right Unscrew Bolts
    G04676734Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  40. Insert guard plate between component compartment wall and engine.
  41. Move engine together with transmission into angled position and lift out of engine compartment by repositioning engine hoist several times, and install in the same way.
    NOTE: When tilting engine, pay attention to rear lifting lug and to oil filter (arrow).
    Fig 29: Identifying Oil Filter
    G04676735Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
  42. Installation is performed in the reverse order.

    Installation note model 140 

    Before installing the engine, install right engine mount in front suspension, left engine mount can be installed with the engine.

  43. Examine front and rear engine mounts.
  44. Examine coolant, oil and fuel hoses.
  45. If automatic transmission fitted, adjust cable for control pressure.
  46. Check tightening torque of oil drain plugs.
  47. Adjust oil level in engine and transmission to correct level.
  48. Pour in coolant, check anticorrosion/antifreeze agent, adjust to correct ratio (20-0100) .
  49. Check idle speed.
    NOTE: If engine is replaced, read fault memory of the following control modules and erase any faults which may be stored.
    • CFI control module
    • LH-SFI control module
    • DI/KSS ignition control module
    • Electronic accelerator (if fitted)
    • Diagnostic module (California), see Diagnosis Manual Engine Volume 2.
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