Remove/install engine

AR01.10-D-2400E

Remove/install engine

1.2.08

 

Remove/install

1

Disconnect ground cable from battery

2

Remove engine cover on inside (1)

3

Remove transmission noise encapsulation (2) and engine noise encapsulation (3)

4

Remove front bumper (4)

 Removal: Unscrew from holder

Pay attention to spacers

 Take out coupling pin (5)

5

Remove radiator grille (6)

AR88.00-D-2115A

6

Remove front trim panel (7)

AR88.00-D-2200A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

7

Drain coolant

AP20.00-D-2080-01B



*BA20.20-N-1001-01B



*BF20.00-N-1001-01A

8

Remove radiator unit together with front end (8)

AR20.20-D-3870A

9

Remove charge air pipe (9) and intake pipe (10)

10

Remove attached parts at intake manifold

AR09.20-D-1310-05A

11

Remove oil filler pipe

12

Slacken poly V-belt

AP13.22-D-1381-01B

13.1

Take poly-V belt off power steering pump

Engine 602.984

 Attach poly V-belt at engine

13.2

Unscrew power steering pump (11)

Engine 602.984

 Installation: Place power steering pump with connected lines to the side and secure to prevent it from slipping

14.1

Disconnect the steering oil return flow hose (17) at oil pan

Engine 602.985

 Drain off steering oil into a clean container, then close off the hose ends.

15.1

Disconnect steering oil pressure line at power steering pump

Engine 602.985

 Unbolt steering oil pressure line from bracket and attach at side in vehicle.



*BA46.30-N-1002-01D

16

Disconnect heating hose on left and right at engine

17

Unscrew vacuum line (A) from vacuum pump

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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

18

Disconnect fuel lines at engine

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

AR47.25-D-1000-01A

19

Separate electric plug connections at engine

 Remove cable ties

AR15.30-D-7100-01B



*352589023700

20

Remove speedometer sensor (13)

 Installation: On vehicles with tachograph newly lead-seal

21

Disconnect engine wiring harness

 Remove cable ties

AR01.00-D-2410A



*352589023700

22

Remove shift lever

AR26.60-D-6600A



*BA26.60-N-1002-01A

23

Remove front exhaust system

 Installation: Install new nuts.

AR49.10-D-7140-01A



*BA49.10-N-1002-01B

24

Unbolt exhaust bracket at transmission

25.1

Separate compressed air line (15)

Engine 602.985

26

Remove clutch slave cylinder (12)

 Place to the side with line connected

AR25.20-D-0150A



*BA25.20-N-1001-01A

27

Unbolt propeller shaft (14) from transmission



*BA41.10-N-1001-01D

28

Slacken propeller shaft intermediate bearing bolts and push propeller shaft to the rear

 Installation: Only tighten the bolts on the propeller shaft center support bearing when the propeller shaft is flange-mounted on the transmission

29

Unscrew engine attachments

 Take off breather cover at transmission if insufficient clearance to floor panel.

AR22.10-D-1260-02A



*BA22.10-N-1005-01A



*BA22.10-N-1006-01A

30

Remove engine with removal fixture

AR01.10-D-2400-01B



*BA22.10-N-1002-01A

31

Install in the reverse order

Number

Designation

Steering 765.841 with engine 602.985

BA46.30-N-1002-01D

Oil pressure line to power steering pump

Nm

40

Number

Designation

Engine
602.984/
985

BA09.20-N-1002-02B

Bolts of mixing housing to intake manifold

Nm

9

Number

Designation

Engine
602.984/
985

BA20.20-N-1001-01B

Coolant drain plug to radiator (reference value)

Nm

3

Number

Designation

Engine 602.984/
985

BA22.10-N-1002-01A

Engine support to front end mount

Nm

68

BA22.10-N-1005-01A

Rear engine support on transmission

Nm

68

BA22.10-N-1006-01A

Rear engine mount on engine support

Nm

38

Number

Designation

Engine 602.980/
984/985

BA25.20-N-1001-01A

Bolt, clutch slave cylinder to clutch housing

Nm

23

Number

Designation

Trans-mission 711.613

BA26.60-N-1002-01A

Shift rail lock bolt

M181.5

Nm

30

Number

Designation

Model
667

Model
668.3, 670

BA41.10-N-1001-01D

Propeller shaft on transmission

M101

Nm

62

62

M121.5

Nm

-

100

Number

Designation

Engine
602.984/
985

BA49.10-N-1002-01B

Flange connection for front exhaust system - turbocharger

Nm

25

Number

Designation

Engine
602.984/985

BF20.00-N-1001-01A

Coolant

Total filling capacity

Liters

10.0

Anticorrosion/antifreeze agent down to -37 °C

Liters

5.0

Anticorrosion/antifreeze agent down to -45°C

Liters

5.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-00A