Remove/install engine

AR01.10-D-2400C

Remove/install engine

21.10.11



Remove/install

1

Remove engine hood

AR88.40-D-3000A

2

Remove center part of front end

AR88.30-D-2302A

3

Remove radiator

AR20.20-D-3865C

4

Remove air filter

5

Detach cover at ventilation housing

AR83.10-D-0010-01C

6

Remove idle speed control (ISC) actuator

AR30.22-D-1152C

7

Detach intermediate flange at intake manifold

AR09.20-D-1310-08C



*BA09.20-N-1002-02A

8

Detach throttle control cable

AR30.10-D-3070-02C

9

Detach coolant line of heating feed and heating return flow

AR20.20-D-7440-01C

10

Detach vacuum lines at intake manifold

 Do not disconnect vacuum line to diaphragm pressure regulator.

AR09.20-D-1310-06C



*BA09.20-N-1004-02A

11

Take off hydraulic lines at power steering pump

AR46.30-D-0500-01C



*BA46.30-N-1003-01A



*BA46.30-N-1005-01A



*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

12

Disconnect fuel lines at engine

AR47.25-D-1000-01C

13

Separate plug connections at PEC control unit

AR07.52-D-1470-01C

14

Disconnect engine wiring harness at starter

AR15.30-D-7100-03C



*BA15.30-N-1002-01A



*BA15.30-N-1003-01A

15

Separate plug connections of engine wiring harness in connector recess

AR01.00-D-2410-01C

16

Remove shift lever

AR26.60-D-6600A

17

Detach exhaust system at exhaust manifold

AR49.10-D-7140-03C



*BA49.10-N-1001-01A

18

Separate plug connection at reversing light switch

AR26.19-D-0001-01C

19

Separate plug connection at PTO switch

 On models fitted with PTO.

AR26.45-D-0021-02C

20

Disconnect propeller shaft at PTO

 On models fitted with PTO.

AR41.20-D-0050-14C



*BA41.20-N-1001-01A

21

Detach hydraulic line at PTO slave cylinder

 On models fitted with PTO.

AR26.45-D-0021-01C

22

Detach slave cylinder at transmission

AR25.20-D-0150-01C



*BA25.20-N-1002-01C

23

Disconnect ground cable at transmission

AR15.00-D-1100-01C



*BA26.10-N-1001-01A

24

Take off speedometer sensor at transmission

AR26.19-D-0001-02C



*BA26.19-N-1001-01B

25

Expose electrical connection of sensor, separate plug connection

AR07.04-D-5303-01C

26

Detach transmission bearing bracket at transmission

AR26.10-D-0020-01C



*BA22.10-N-1005-01H



*BA22.10-N-1006-01H

27

Separate plug connection at kickdown solenoid valve

 On models fitted with automatic transmission.

AR27.19-D-6200-01C

28

Detach selector lever Bowden cable from transmission

 On models fitted with automatic transmission.

AR27.60-D-0100-02A

29

Separate plug connection at starter lockout switch

 On models fitted with automatic transmission.

AR27.10-D-0240-01C

30

Take off pulse generator at sensor

 On models fitted with automatic transmission.

AR27.19-D-0002-01C



*BA27.19-N-1002-02B

31

Detach propeller shaft at transmission

AR41.10-D-0050-14C



*BA41.10-N-1001-01B



Notes on installing propeller shaft

MODEL 901, 902, 903, 904

AH41.10-N-0001-01A

32

Detach transmission bracket at automatic transmission

AR27.10-D-0500-06C



*BA22.10-N-1005-01H



*BA22.10-N-1006-01H

33

Remove engine with removal fixture

 On models fitted with automatic transmission.

AR01.10-D-2400-01C

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



*BA22.10-N-1002-01H

34

Install in the reverse order

Number

Designation

Engine 111.979/
984

BA09.20-N-1002-02A

Intermediate flange on intake manifold

M8

Nm

21

BA09.20-N-1004-02A

Vacuum line to vacuum connection of intake manifold

Nm

30

Number

Designation

Engine 111.979/
984

BA15.30-N-1002-01A

Nut (terminal 30) on starter

Nm

15

BA15.30-N-1003-01A

Nut (terminal 50) on starter

Nm

6

Number

Designation

Engine 111.979

BA22.10-N-1002-01H

Engine support on front end mount

Nm

83

BA22.10-N-1005-01H

Rear engine support on transmission

Nm

45

BA22.10-N-1006-01H

Rear engine mount on engine support

Nm

45

Number

Designation

Engine 111.979

BA25.20-N-1002-01C

Screw/bolt, clutch slave cylinder to transmission

Nm

23

Number

Designation

Trans-mission 711.603

Trans-mission 711.612

BA26.10-N-1001-01A

Screw/bolt, manual transmission to engine

Nm

55

38

Number

Designation

Trans-mission
711.612

BA26.19-N-1001-01B

Screw/bolt, speedometer sensor to transmission

Nm

8

Number

Designation

Transmissions 722.330/337

Transmission 722.332/375/376

BA27.19-N-1002-02B

Screw/bolt, pulse generator to transmission housing

Nm

8

8

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

BA41.20-N-1001-01A

Propeller shaft to PTO

Stage 1

Nm

23

Stage 2

°

-

Number

Designation

Model
901.0/3/4,
902.0/3/4,
903.0/3/4,
904.0/3/4

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

-

Nm

-

VDA pump

Nm

38

VT pump

Nm

48

BA46.30-N-1005-01A

Return line to power steering pump

Nm

38

Number

Designation

Engine
111.979/
984

BA49.10-N-1001-01A

Flange connection for front exhaust system - exhaust manifold

Nm

23