Remove/install engine

AR01.10-D-2400A

Remove/install engine

21.10.11

 

Remove/install

1

Disconnect ground cable at battery

2

Remove engine hood (1)

AR88.40-D-3000A

3

Remove radiator (4)

AR20.20-D-3865A

4

Remove air filter housing (2).

5

Remove attached parts at intake manifold

AR09.20-D-1310-05A



*BA09.20-N-1002-02B

6

Disconnect LH and RH heater hose (5)

7

Detach vacuum lines (9, 10) from vacuum pump

8

Take off hydraulic lines at power steering pump

AR46.30-D-0500-01A



*112589007200

Danger!

Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel.

No fire, sparks, open flames or smoking.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

9

Disconnect fuel lines at engine

 Press together the cams of the coupling for this Operation step.

AR47.25-D-1000-01A

10

Remove cover (6) from ventilation box

11

Detach electric plug connections at engine

AR15.30-D-7100-01A



*BA27.40-N-1001-01B

12

Remove shift lever

AR26.60-D-6600A

13

Unscrew exhaust system from turbocharger and retaining plate

 Installation:
Replace the copper hexagon nuts.

AR49.10-D-7140-01A



*BA49.10-N-1002-01B

14

Detach power take-off connections

 On models fitted with PTO.

AR26.45-D-0010-04A



*BA41.20-N-1001-01A

15

Unbolt propeller shaft (8) from transmission

AR41.10-D-0050-02A



*BA41.10-N-1001-01B



Notes on installing propeller shaft

MODEL 901, 902, 903, 904

AH41.10-N-0001-01A

16

Remove clutch slave cylinder

 Place to one side with line connected, see: 

Remove clutch slave cylinder

AR25.20-D-0150A

17

Remove speedometer sensor (7)

18

Unhook shift cable from automatic transmission

 On models fitted with automatic transmission

19

Disconnect electrical connectors from automatic transmission

 On models fitted with automatic transmission

AR27.19-D-0750-01A

20

Detach vacuum line from vacuum unit

 On models fitted with automatic transmission

21

Unscrew engine attachments

AR22.10-D-1260-02A



*BA22.10-N-1005-01A



*BA22.10-N-1006-01A

22

Remove engine with removal fixture

AR01.10-D-2400-01A



*BA22.10-N-1002-01A

Engine support device, engine hoist
gotis://A_01_09.0

23

Install in the reverse order

Number

Designation

Engine
602.980

BA09.20-N-1002-02B

Screw/Screw/Screw/bolts, mixing housing to intake manifold

Nm

9

Number

Designation

Engine 602.980

BA22.10-N-1002-01A

Engine support on front end mount

Nm

83

BA22.10-N-1005-01A

Rear engine support on transmission

Nm

45

BA22.10-N-1006-01A

Rear engine mount on engine support

Nm

45

Number

Designation

Transmission 722.330/332
/337/375/376

BA27.40-N-1001-01B

Screw/bolt, transmission housing to crankcase

Nm

55

Number

Designation

Model
690.6, 901, 902, 903, 904, 905 except Minibus Sprinter Low Floor

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Screw headE18

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

PTO 28-2b (with output flange Code N07) with transmission 711.612 in model 901, 903, 904.0/4

PTO 28-2b (with output flange code N07) with transmission 711.620 in model 901.6, 902.6, 903.6, 904.6

BA41.20-N-1001-01A

Propeller shaft to PTO

Stage 1

Nm

23

23

Stage 2

°

-

-

Number

Designation

Engine
602.980

BA49.10-N-1002-01B

Flange connection for front exhaust system - turbocharger

Nm

23