Diesel engines — removal and installation (Mercedes-Benz C-Class W201)

Removal

Note: This operation requires a suitable hoist and winch.

1. Perform the actions described in paragraph 4, items 1-8, inclusive, taking into account that there is no need to remove the air cleaner.

2. On non-turbo models, remove the air intake duct, then unfasten the fasteners and remove the air cleaner cover and filter (see fig. 6.2).

Fig. 6.2. Remove the air cleaner cover and filter

3. On turbo models, remove the compressor air inlet pipe.

4. Working in the engine compartment, disconnect all necessary hoses and pipes so that they do not interfere with engine removal. Note the location and routing of all hoses and pipes so as not to mix them up during installation. Where provided, release all hoses and vacuum pipes from their holders or brackets.

5. Similarly, in the engine compartment, disconnect the wires from the corresponding parts and connectors. Remember the location and routing of all connections so as not to mix them up during installation. Release all wires and wiring harnesses from the holders and brackets on the engine.

6. On models with air conditioning, remove the accessory drive belt as described in Chapter 1. Loosen the air conditioning compressor bolts as described in Chapter 3 and support it in the engine compartment, separating it from the engine but leaving the coolant pipes connected,

7. Loosen the union nuts and disconnect the supply and return lines from the fuel filter and/or fuel injection pump. Where necessary, hold the unions from turning.

8. Disconnect the throttle cable from the throttle control lever (refer to Chapter 4), then release the cable from all brackets on the engine and move it to the side.

9. Unscrew the power steering reservoir cap and drain as much fluid as needed. Use a large syringe. Replace the reservoir cap when empty.

Article text obtained from the website www.MercedesMan.ru

10. Where required, loosen the nipples and disconnect the fuel hoses from the hydraulic pump of the suspension leveling system / power steering. Release the pipes from the holders and brackets on the engine.

11. Where provided, remove the wheel arch liner from the left side of the wheel arch, then unscrew the fittings and disconnect the oil pipes from the oil heat exchanger located under the wheel arch (refer to Chapter 2G for further information).

12. Where it is installed, unscrew the engine speed sensor from the flywheel side and release the wire from the holders. Leave the sensor with the wiring harness in the engine compartment, taking measures not to damage it.

13. On models with automatic transmission, unscrew the heat exchanger tubes from the engine pan and remove the unit.

14. Disconnect the brake booster vacuum hose from the vacuum pump (see Chapter 9).

15. Perform the actions described in paragraph 4, items 23-28, inclusive.