Preparing to remove the 612 series engine
Preparing to remove the 612 series engine
1. Illustrative material on preparation for engine removal is presented in the illustrations, to which all references found in the text refer.
2. Open the hood and support it in an upright position.
3. Disconnect the negative cable from the battery.
4. Remove the cylinder head covers.
5. Remove the lower section of sound insulation.
6. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).
7. Remove the cooling system expansion tank (1).
8. Disconnect the cooling system hose (2) running from the thermostat housing to the radiator.
9. Remove the air intake (4/3).
10. Remove the air intake sleeve (4/2).
11. Remove the electric fan (3) of the cooling system.
12. Install the radiator/compressor protection screen.
13. Remove the accessory drive belt (6).
14. Pump out the hydraulic fluid from the power steering reservoir (see Chapter Filling and "bleeding" the steering pump).
15. Disconnect the power steering line (5) from the radiator.
16. Disconnect the power steering line (13) from the steering pump - immediately seal the open ends of the hose and the inlet fitting.
17. Disconnect the vacuum hose (10) from the boost control unit. Also disconnect the vacuum lines (11 and 12) going to the mixing chamber and the vacuum pump.
18. Disconnect the air hose (19) from the turbocharger.
19. Remove the tube (110/5) supplying boost air to the mixing chamber.
20. Disconnect the cooling system pipes (14 and 15) from the water pump.
21. Disconnect the fuel cooler hose (16).
22. Disconnect the low-temperature cooler hose (17) and remove the hose (18) connected to the thermostat housing.
23. Disconnect the fuel supply pipe (8) of the preheating system.
24. Disconnect the return pipe (9) from the fuel cooler.
25. Disconnect the engine wiring connector(s).
26. Remove the pipe (19) going from the turbocharger (110) to the air cooler.
27. Disconnect the electrical wiring from the A/C compressor.
28. Unbolt the K/V compressor (21).
29. Suspend the engine on a winch.
30. Remove the bolts from the holes for installing the support on the transmission housing.
31. Support the transmission.
32. Remove the transmission-to-engine mounting bolts.
33. Loosen the spring loaded fastener securing the primary catalytic converter to the main three-way catalytic converter (TWC).
34. Loosen the fastening elements of the front support of the power unit suspension (22) to the vehicle frame.
35. Separate the engine from the transmission and carefully remove it from the engine compartment of the vehicle.
36. Installation is carried out in reverse order.
M628
Preparing to remove the 628 series engine
Preparing to remove the 628 series engine
1. Illustrative material on preparation for engine removal is presented in the illustrations, to which all references found in the text refer.
2. Open the hood and support it in an upright position.
3. Disconnect the negative cable from the battery.
4. Lift the power unit cover.
5. In a car service workshop, discharge the air conditioning system.
6. Remove the left and right headlights (see Chapter Body).
7. Remove the upper frame cross member (see Chapter Body).
8. Remove the windshield washer fluid reservoir (see Chapter Body).
9. Remove the air cleaner assembly (18).
10. After pumping out the hydraulic fluid, remove the reservoir (21) of the steering pump from the support plate of the intake air distribution hose.
11. Remove the left front wheel.
12. Remove the wheel arch protection liner.
13. Working through the wheel arch, separate the refrigeration line (13) from the A/C compressor.
14. Also through the arch, disconnect the fuel lines (14).
15. Remove the lower section of the sound insulation.
16. Drain the cooling system (see Chapter Checking the cooling system and frost resistance of the coolant, replacing the liquid).
17. Disconnect the air hoses (9 and 10) of the right and left turbochargers and the boost air hose (12) from the cooler (11).
18. Loosen the primary catalytic converter mounting clamps on the left and right turbochargers.
19. Remove the transmission dome mounting bolts from the engine (except the lower ones).
20. Loosen the nuts of the left and right powertrain suspension supports.
21. Remove the cover (30) of the service window and unscrew the bolts securing the rotation converter to the engine starter drive disk equipped with a toothed ring gear.
22. Disconnect the left and right drain hoses (28 and 29) from the transmission case.
23. Disconnect the ventilation (5) and supply (4 and 6) hoses from the radiator (1).
24. Disconnect the ATF cooling lines (2 and 3) from the radiator.
25. Disconnect the power steering fluid cooling lines (7 and 8) from the radiator.
26. Remove the electric cooling fan (see Chapter Cooling, heating and air conditioning systems).
27. Install the radiator/compressor protection screen.
28. Disconnect the low-temperature cooler hoses (15 and 17).
29. Disconnect the heater return hose (16).
30. Disconnect the MAF sensor wiring connectors (B2/6 and B2/7).
31. Remove the air distributor (20) with the air cleaner inlet hose (24).
32. Remove the cooling system expansion tank (19).
33. Remove the heat exchanger feed hose on the left side of the engine compartment bulkhead.
34. Remove the cooling system circulation pump (additional equipment) from the battery shield and, without disconnecting the hoses, move it to the side.
35. Loosen the fastener and remove the ATF filler tube (27) from the cylinder head cover.
36. Disconnect the shut-off valve inlet port vacuum line (23) and the cooling system vent hose from the fuse/relay box.
37. Disconnect the shut-off valve inlet port vacuum line (23) from the brake booster servo.
38. Disconnect the refrigeration line (26) from the A/C compressor.
39. Disconnect the pressure line (25) from the steering pump.
40. Disconnect the drive cable from the position sensor (22).
Material borrowed from an online resource (mercedesman)
41. Remove the position sensor (22) from the bulkhead.
42. Disconnect the engine wiring connector(s).
43. Suspend the engine on a winch, completely unloading the front supports of the power unit suspension.
44. Support the transmission.
45. Remove the lower bolts securing the transmission dome to the engine.
46. Pull the engine forward to separate it from the transmission, then carefully remove it from the engine compartment.
47. Installation is carried out in reverse order.
48. Fill the cooling system with fresh coolant, charge the cooling system at a service station. Check the ATF level, make the appropriate adjustments if necessary (see Chapter Replacement and checking of ATF level, replacement of AT filter).
49. Finally, connect the STAR DIAGNOSIS reader to the DLC and query the processor memory for trouble codes (DTC). After making the necessary corrections, clear the system memory.