AR01.10-B-2401B | Remove/install engine with transmission | 12.02.16 |
Cumbustion engine 457, 460 with Vehicle 634.011D, 634.061D, 634.081D
Cumbustion engine 457, 476 with Vehicle 664.231
B01.10-0014-06
Shown in vehicle 634.061 with 457.932 engine
1 Alternator cooling hose
2 Alternator
3 Intermediate fan pulley
4 Cross-member
5 Fuel pipe from pre-filter to fuel filter
6 Intake line- reservoir to hydraulic power steering pump
7 Pressure line - hydraulic pump to hydraulic power steering case
8 Compressed air line from air compressor to compressed air tank
9 Exhaust pipe
10 Intake air hose for the air compressor
11 After-cooler charge air outlet pipe
A Fan belt
B Vibration damper belt
c Crankshaft belt
B46.30-0051-01
B01.20-0010-01
Shown in vehicle 634.061 with 457.932 engine
1 Alternator cooling air hose
6 Intake line- reservoir to hydraulic power steering pump
7 Pressure line - hydraulic pump to hydraulic power steering case
10 Intake air hose for the air compressor
12 Pipe- intake air for the turbocharger
B22.10-0025-01
B25.20-0036-01
Shown in vehicle 634.061 with 457.932 engine
13 Damper- rear engine mount bracket
14 rear bracket - engine mount
15 Clutch booster cylinder
B09.00-0002-01
B22.10-0026-01
Shown in vehicle 634.061 with 457.932 engine
16 Fuel pipe - fuel pre-filter
17 Piping- charge air from turbocharger to after-cooler
18 Cross-member for gearbox attachment
19 Gearbox shift-cable
| Removing and installing | ||
Danger! | Risk of injury in the eyes from hydraulic steering fluid jets, at high pressure. Poisoning risk by swallowing hydraulic steering fluid | Slacken the end of stroke bolt, maximum 5 turns. Wear safety goggles. | |
Danger! | Risk of eye and skin injury, from burns caused by overheated coolant or steam.Risk of poisoning due to coolant ingestion | Open the cooling system only when the temperature is below 90 °C. Open the cap slowly and let the excessive pressure out. Coolant should not be kept in beverage bottles. Use gloves, appropriate clothes and protective glasses. | |
1 | Open the rear left side flap | ||
Danger! | Risk of explosion by detonating gas. Risk of poisoning and ulceration by swallowing battery acid.Risk of skin and eye injury when handling batteries | Fire, sparks, open flame and smoking is forbidden. Use acid protective gloves, -clothes and goggles. Keep battery acid only in suitable containers and duly identified. | |
2 | Detach the battery ground lead | ||
3 | Open the rear right side flap | ||
4 | Open the inspection hatches for engine and gearbox on vehicle floor | ||
5 | Open the rear flap of engine compartment | Installation:Only close the engine compartment rear end flap after checking and, if necessary correcting the coolant level. | |
6 | Remove the bumper | ||
7 | Remove the rear end closing cross-member (4) | ||
8 | Remove the belts (A, B, C) | ||
9 | Remove the fan intermediate pulley (3) | ||
10 | Drain the coolant | ||
| Change the coolant | ||
| General information on engine coolant | ||
11 | Remove all engine coolant hoses | Only remove the cooling water hoses and tubes necessary for the engine removal. If necessary, remove also hose and pipe brackets. | |
12 | Remove all retarder coolant hoses | Only remove the cooling water hoses and tubes necessary for the engine removal. If necessary, remove also hose and pipe brackets. | |
13 | Remove the cooling hose (1) from the alternator (2) | ||
14 | Remove the charge air outlet pipe (11) from the after-cooler to the intake manifold | ||
15 | Remove the intake air hose (10) from the intake air pipe to the air compressor | ||
16 | Remove the charge air pipe (8) from the air compressor to the compressed air tank | ||
17 | Remove the intake air pipe (12) for the turbocharger | ||
18 | Remove the charge air (17) from the turbocharger to the after-cooler | ||
19 | Remove the cabin electric wires set of the control unit (MR) | Installation:Utilize new clamps. Observe a routing free of interference for the cab electric wiring harness. | |
20 | Remove the hydraulic fluid low pressure line (6) and high pressure line (7) at the hydraulic power steering case | Installing: Replace the sealing rings. Catch the running off hydraulic fluid in a suitable container. | |
21 | Remove the fuel line (16) from the fuel pre-filter to the engine | Installing: Replace the sealing rings. | |
22 | Remove the fuel filter piping (5) | Installing: Replace the sealing rings. | |
23 | Remove the exhaust pipe (9) from the engine-brake drive cylinder to the silencer assembly | Installing: Check the seals for wear and replace if necessary. | |
| Indications on self-locking bolts and nuts | All models | |
24 | Remove the transmission shaft | ||
25 | Remove the clutch booster cylinder (15) | ||
26 | Disconnect all electric and pneumatic connections at the gearbox | ||
27 | Detach the gearbox shift cables (19) | ||
28 | Position the lifting device under the engine/gearbox assembly | Fasten the engine/gearbox set on the device in such a way that the set is steady and does not fall during the removal | |
29 | Loosen the top eyelet of damper (13) and remove rear engine bracket (14) | ||
30 | Unscrew the bolts and loosen the gearbox from the attachment cross-member (18) | ||
31 | Remove the engine/gearbox assembly out from the vehicle | ||
32 | Install in reverse order of operations | ||
33 | Top-up the cooling system | Utilize new coolant. | |
| Renew the coolant | ||
34 | Complete the power steering hydraulic fluid level | Utilize new hydraulic fluid. | |
35 | Check the engine oil level, if necessary fill it up | ||
| Change the engine oil and the oil filter | ||
36 | Perform a test ride with the vehicle | During the journey, check the operation and tightness of the components and respective connections. |
Engine mount, engine support
Número | Denominação | Engine 457.9 | |||
BA22.10-B-1004-01C | Fastening of engine rear mount to support (mounting of engine mount) | M12x1.5 | Nm | 90 | |
M14x1.5 | Nm | 150 | |||
M16x1.5 | Nm | 180 | |||
BA22.10-B-1005-01C | Fastening of the gearbox | M10x1,5 | Nm | 58...63 | |
M14x1.5 | Nm | 150 | |||
M16x1.5 | Nm | 180 | |||
M18x1.5 | Nm | 330 | |||
M20x1.5 | Nm | 400 | |||
M22x1,5 | Nm | 640 | |||
Clutch operator
Número | Denominação | 457.916/932 engine with WGTZ 430 clutch | |||
BA25.20-B-1002-01H | Clutch reinforcement cylinder fastening bolt | M8 | Nm | 20...22 | |
M10 | Nm | 54...62 | |||
Power steering pump
Número | Denominação | Engine 457.9, 460.984 | |||
BA46.30-B-1002-01B | Suction piping on the hydraulic steering pump | Nm | 40 | ||
BA46.30-B-1003-01B | Pressure piping on the hydraulic steering pump | M22x1.5 | Nm | 80 | |
Fuel filter
Fuel lines/hoses