Remove/install engine (version 2) - RA0100119A300X(01-0300)

Preceding work:

Air cleaner (4) removed (09-0015) .

Bottom engine compartment panel removed (Maintenance Manual 6190).

Radiator removed (20-4200) .

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

1. Models 124, 129, 140 
   Fig 1: Identifying Engine Remove/Install Components - Models 124, 129, 140

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

   Ground cable at battery	disconnect, connect.
   Coolant at crankcase	drain.
   If AC fitted: guard plate at condenser	attach, remove.
   Model 140: left Bowden cable (engine compartment lock)	detach, attach.
   Heating water lines at rear of intake manifold and at connection pipe to rear of crankcase	detach, attach.
   Viscous fan clutch with fan (2)	remove, install (20-3120) .
   If AC fitted:	remove, install (13-3420) .
   poly V-belt (3)
   Fuel lines	take off, seal with special tool 000 589 40 37 00, fit on. Open fuel filler cap briefly beforehand.
   Electrical connections (engine wiring harness)	detach, attach.
   Vacuum lines	detach, attach.
   Bowden cable (accelerator control)	remove, install (30-0025) .
   Model 124: accelerator control linkage at rear	remove, install.
   Vacuum line of brake servo unit	unbolt, bolt on.
   Power steering pump, oil in reservoir	extract, special tool 112 589 00 72 00. Adjust oil to correct level (46-0715) .
   Oil lines of power steering pump	detach, seal, attach.
   If air injection fitted: air pump plug connection	detach, plug in.
   Model 124: front bumper	remove, install.
   Model 124: right headlamp	remove, install.
   Model 124: air duct, left engine mount cooling	remove, install.
   Model 140: oil cooler line bracket	unbolt, bolt on.
   Oil cooler lines at air-to-oil cooler (13) and (14)	unbolt, seal, bolt on (18-1300) .
   Model 124: left oil cooler line (13) at oil sump	unbolt, bolt on.
   If level control fitted: high pressure hose	unbolt, bolt on.
   Model 124: left oil line, automatic transmission	unbolt, bolt on.
   Bolt for piping behind AC compressor	unbolt, bolt on (25 Nm).
   AC compressor (11) with piping connected	detach, place to the side, attach.
   Plug connection, oxygen sensor (6) (lambda sensor)	disconnect, connect.
   Exhaust system (7) complete	remove, install (49-0045 , 49-0170 ).
   Shield over starter	unbolt, bolt on.
   Model 129: electrical connection, starter	detach, attach.
   Wiring harness, starter and alternator from engine and transmission	unbolt, bolt on.
   Model 124: strut below oil sump	unbolt, bolt on.
   Propeller shaft of flexible coupling (8)	detach, attach. Replace self-locking nuts. NOTE: Flexible coupling remains on transmission.
   Clamping nut and intermediate bearing attachment of propeller shaft	slacken, tighten.
   Ground cable at transmission	unbolt, bolt on.
   Rear engine carrier (10) without engine mount	remove, install (22-2120) .
   Bracket of exhaust at transmission	unbolt, bolt on.
   Shift rod at transmission	detach, attach.
   Electrical connections at transmission	disconnect, connect.
   Front engine mounts (12) on left and right from below	unbolt, bolt on (22-2110) .
   Model 124: sealing strip of component compartment panel	pull off, fit on.
   Engine hoist at lifting eyes	attach, detach.
   Engine with engine hoist	move into angled position and raise.
   Model 129: wiring harness of alternator	unbolt, bolt on.
   Engine	remove, install.
   Front and rear engine mounts	examine.
   Coolant, oil and fuel hoses	examine.
   Automatic transmission, Bowden cable for control pressure	adjust (27-110) .
   Idle speed	check, adjust.
   Oil drain plugs	check tightening torques.
   Oil level in engine and transmission	adjust to correct level.
   Coolant	pour in, check anti-corrosion/anti-freeze concentration and adjust to correct level (20-0100) .
   Cooling system	check for leaks, special tool 124 589 15 21 00 (20-0170) .
   Engine	run.
   Engine leaks	check. NOTE: Faults stored as a result of disconnecting cables or simulation during removal and installation or test operations, should be processed and erased in the fault memories after completing the work. Re-code or normalize radio and power windows, as appropriate. Perform final control actuations. Diagnosis Manual Volume 2, Index 0: Connecting and using test equipment.

   Special tools 

   Fig 2: Identifying Special Tool (001 589 66 21 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   Fig 3: Identifying Special Tool (124 589 15 21 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   Fig 4: Identifying Special Tool (112 589 00 72 00)

   Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
   COMMERCIALLY AVAILABLE TOOLS
   
   

   Engine hoist No. 3188	e.g.	Backer GmbH
   self-locking		and CO KG D-42895 Remscheid

   SHOP-MADE TOOL
   
   

   Guard plate for radiator/condenser

   Dimensions approx. 400x680x1