Remove/install engine with transmission · ar0110g2401f · Mercedes-Benz WIS

AR01.10-G-2401F

Remove/install engine with transmission

02.05.2017

Engine

926.969 in model 437.467 with transmission 723.68

Modification notes

15.06.2015	Mutter Klemme 30 an Starter		BA15.30-N-1002-01M
30.07.2015	Nut, electrical line to alternator terminal B+	Engine 926.969	BA15.40-N-1009-01N
31.07.2015	Document completely revised.

G01.10-3159-79

1	Air intake pipe	8	Nut
2	Air cleaner housing	9	Nut
3	Charge air pipe	10	Electrical connector
4	Charge air pipe	11	Nut
5	Charge air pipe	A31	Intake air preheating control unit (grid heater) with an integral heater flange (with code M89 (Intake air preheating))
6	Hydraulic pump (with code H19 (Hydraulic system without oil supply) or with code HH3 (Hydraulic system with oil supply))	G2	Alternator
7	Bolts	M1	Starter

G01.10-3157-79

12	A/C compressor (with code M25 (A/C compressor reinforced))	19	Cross plate
13	Coolant pipe	20	Fuel line
14	Coolant expansion reservoir	21	Fuel line
15	Steering shaft intermediate bearing	22	Fuel line
16	Steering shaft	23	Fuel line
17	Compressor	24	Electrical line
18	Power steering pump	G3	Additional alternator

G27.45-3101-71

G01.10-3158-01

G01.10-3127-71

25	Electrical connection (with code NU4 (PTO of A/T, 8 o'clock, N-rotational speed, pump))
26	Power take-off (with code NU4 (PTO of A/T, 8 o'clock, N-rotational speed, pump))

Union nut

28	Engine supporting arm
29	Screw

G01.10-3160-78

1	Air intake pipe	37	Cross strut
30	Turn signal lamp	38	Bracket
31	Bracket	39	Bracket
32	Fluid reservoir (with code M25 (A/C compressor reinforced))	40	Compressed-air line
33	Compressed-air line	41	Bracket
34	Bracket	42	Compressed-air line
35	Bracket	43	Heat shield
36	Compressed air lines	44	Exhaust pipe

G01.10-3161-78

45	Load lifter	47	Screw
45.1	Chain link	48	Electrical wiring harness
45.2	Chain link	49	Electrical connector
46	Transmission carrier

 Warning	Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.	Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.	AS00.00-Z-0005-01A
 Danger	Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.	No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. Wear protective clothing when handling fuel.	AS47.00-Z-0001-01A
 Danger	Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.	Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.	AS83.00-Z-0001-01A
Topical note	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
 	Remove/install
 Danger	Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries	No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.	AS54.10-Z-0001-01A
1	Disconnect battery ground line
Topical note	Notes on battery		AH54.10-P-0001-01A
		 See information from vehicle manufacturer.
2	Remove body	 See information from vehicle manufacturer.
3	Drain air conditioning system	With code M25 (A/C compressor reinforced)
		 See information from vehicle manufacturer.
4	Remove radiator unit		AR20.20-G-3871F
5	Remove refrigerant lines on A/C compressor (12)	With code M25 (A/C compressor reinforced)
		 See information from vehicle manufacturer.
6	Disconnect electrical connection at refrigerant compressor (12)	With code M25 (A/C compressor reinforced)
7	Mark installation position of fuel lines (20, 21, 22, 23)
8	Disconnect fuel lines (20, 21, 22, 23) and collect escaping fuel	 Installation: Observe markings.
9	Attach fuel lines (20, 21, 22, 23) to frame
10	Remove electrical line (24) on additional alternator (G3) and expose up to the frame	 Nut, electrical line to alternator terminal B+	*BA15.40-N-1009-01N
11	Remove coolant pipe (13) completely
12	Remove steering shaft intermediate bearing (15) from frame	 Steering shaft intermediate bearing to frame	*BA46.10-N-1009-05I
13	Tie steering shaft (16) to the frame
14	Remove power steering pump (18) from compressor (17) and collect escaping fuel	 Do not disconnect hydraulic lines on the power steering pump (18).
		 Installation: Replace sealing ring on power steering pump (18).
		 Bolt, power steering pump to compressor	*BA46.30-N-1001-01K
15	Fasten power steering pump (18) to frame
16	Attach turning device for engine		AR03.30-G-1600-03B
		 Installation: Coat sealing surface between timing case and cap with the sealant Loctite 5970.
		 Inspection hole cap to timing case	*BA01.60-N-1002-01J
		Sealant, Loctite 5970, 50 ml	*BR00.45-Z-1013-01A
		 Turning device	*904589046300
17	Remove cross plate (19)	 Installation: Turn flywheel with  cranking device until the guides on the cross-plate (19) on the compressor crankshaft (17) are horizontal. Secure cross plate (19) against sliding with high-temperature grease.
		High-temperature grease	*BR00.45-Z-1051-06A
18	Mark installation position of the coolant hoses between coolant expansion reservoir (14) and engine
19	Disconnect all coolant hoses between coolant expansion reservoir (14) and engine	 Installation: Observe marked installation position.
20	Mark installation position of the coolant hoses between auxiliary heater and engine	With code F43 (Auxiliary heater with engine preheating)
21	Disconnect all coolant hoses between auxiliary heater and engine	With code F43 (Auxiliary heater with engine preheating)
		 Installation: Observe marked installation position.
22	Remove exhaust pipe for auxiliary heater from engine	With code F43 (Auxiliary heater with engine preheating)
23	Remove air intake pipe (1)
24	Remove air filter housing (2)
25	Disconnect electrical connections on intake air preheating control unit (grid heater) together with the integral heater flange (A31) and expose electrical lines up to the frame	With code M89 (Intake air preheating)
26	Remove charge air pipe (5)
27	Remove charge air pipes (3, 4)
28	Expose electrical connection (10) and electrical wiring harness to the engine
29	Unscrew nut (8) on alternator (G2) and expose electrical line up to the frame	 Nut, electrical line to alternator terminal B+	*BA15.40-N-1009-01N
30	Disconnect air line (42) for valve fitting of the engine brake
31	Remove bracket (41) for air line (40) from engine
32	Remove air line (40) from bracket (34) and expose up to the frame	 Installation: Secure air line (40) with electrical wiring harness (48) to bracket (34).
33	Remove exhaust pipe (44) completely
34	Remove heat shield (43) on valve fitting for engine brake
35	Unscrew nut (9) on starter (M1) and expose electrical line up to the frame	 Nut, circuit 30 to starter	*BA15.30-N-1002-01M
36	Unscrew nut (11) and expose ground line up to the frame
37	Remove underride guard below the hydraulic pump (6)	With code H19 (Hydraulic system without oil supply) or with code HH3 (Hydraulic system with oil supply)
38	Remove poly-V belt for hydraulic pump (6)	With code H19 (Hydraulic system without oil supply) or with code HH3 (Hydraulic system with oil supply)
			AR13.22-G-1202F
39	Remove hydraulic pump (6) from engine	With code H19 (Hydraulic system without oil supply) or with code HH3 (Hydraulic system with oil supply)
			AR55.30-G-0025-04F
		 Bolt, poly-V belt tensioning device to bracket of hydraulic pump	*BA13.25-N-1002-01L
		 Bolt, hydraulic pump bracket to crankcase	*BA55.30-N-1006-03B
40	Detach electrical connection (25) from power take-off (26)	With code NU4 (PTO automatic transmission, 8 o'clock, N-rotational speed, pump)
41	Remove adaptation or connections from power take-off (26)	With code NU4 (PTO automatic transmission, 8 o'clock, N-rotational speed, pump)
		 See information from vehicle manufacturer.
42	Unscrew union nut (27) from compressed air line
	Check
43	Check air line at the union nut (27) for carbonization	If there are complaints:
		
		Likewise check the compressed-air line on the compressor (17) and the compressed-air line on the four-circuit protection valve for carbonization and replace any carbonized parts.
44	Disconnect electrical connection of the turn signal lamp (30)
45	Completely remove bracket (31) from the fender liner
46	Mark air line (33) and remove from valve block	 Installation: Observe marking.
47	Expose air line (33) up to the frame
48	Remove refrigerant lines from fluid reservoir (32)	With code M25 (A/C compressor reinforced)
		 See information from vehicle manufacturer.
49	Remove bracket (38) from bracket (39)
50	Remove bracket (39) from cross strut (37) and from frame
51	Remove bracket (39) with attached detachable parts and air lines (36) from frame and fasten to left fender liner
52	Remove bracket (35) together with cross strut (37)
53	Remove propeller shaft between transmission and transfer case	 Nut, propeller shaft to output flange	*BA27.10-N-1001-04I
54	Disconnect electrical connection (49) at transmission
55	Remove screw/bolts (47) from left and right on transmission	 Front transmission carrier to engine mount	*BA27.10-N-1009-04I
56	Remove screw/bolt (29) on engine support arm (28)	 Screw/bolt, engine support to engine mount	*BA22.10-N-1010-01M
57	Attach crane with the load lifter (45) to the engine and to the transmission carrier (46)	 The electrical wiring harness (48) must be located behind the chain links (45.2).
58	Remove engine with transmission	 While raising, check that all the lines or components between the engine or transmission and the frame are de-energized, if necessary, disconnect any further connections. Otherwise damage could occur to the lines or assembly parts.
		 Installation: When lowering the engine with the transmission, put on screw/bolts (29, 47).
59	Remove transmission from engine	If required.
			AR27.10-G-0500-07F
	Guide pin used to install the transmission		WF58.50-A-2710-01LA
		Loctite 5203 sealant	*BR00.45-Z-1015-01A
		Sealant, Loctite 5970, 50 ml	*BR00.45-Z-1013-01A
		Long-life grease	*BR00.45-Z-1001-06A
		 Bolt, transmission to timing case	*BA27.10-N-1002-04I
		 Bolt, torque converter to drive plate	*BA27.10-N-1003-04I
		 Center transmission carrier to rear transmission carrier	*BA27.10-N-1007-04I
		 Front transmission carrier to engine timing case	*BA27.10-N-1008-04I
		 Transmission bracket	*437589004000
		 Turning device	*904589046300
60	Install in the reverse order
61	Evacuate air conditioning system, charge it, and then check system to make sure that it functions correctly and leaktightness	With code M25 (A/C compressor reinforced)
		 See information from vehicle manufacturer.
	Check
62	Start engine and run at idle speed for about 1 minutes	 Start engine with the starter (M1) for a maximum of 90 seconds. Repeat starting procedure after a break of approx. 2 minutes at the earliest. Do not rev up the engine before the full oil pressure is indicated. Engine damage can occur otherwise.
		Oil pressure	*BE18.00-N-1001-01J
63	Switch off engine and check for leaktightness
64	Check engine oil level at electric display	 See owner's manual.
65	Check coolant level
			AP20.00-G-2010C
66	Check transmission oil level
			AP27.00-G-2710FA
67	Read out fault memory and clear
			AD00.00-G-2000-04B
		 Stored faults, which may result from lines being disconnected or from simulation during assembly or testing, have to be processed and cleared in the fault memories after completing the work.
	Update Vehicle Documentation (VeDoc)
68	Document engine number in VeDoc	Only if a remanufactured engine is installed.

Check values for oil pressure

Number	Designation			Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96
BE18.00-N-1001-01J	Oil pressure	at idle speed	bar	0,5
		at maximum engine speed	bar	2,5

 Timing case

Number	Designation		Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96
BA01.60-N-1002-01J	Inspection hole cap to timing case	Nm	25

 Belt tensioning device

Number	Designation		Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96
BA13.25-N-1002-01L	Bolt, poly-V belt tensioning device to bracket of hydraulic pump	Nm	50

 Starter

Number	Designation			Engine 900.91/92, 902.92/93, 904.92/95, 906.935/95, 924.91/92/93, 926.96
BA15.30-N-1002-01M	Nut, circuit 30 to starter	M10	Nm	18

 Alternator

Number	Designation			Engine 926.969
BA15.40-N-1009-01N	Nut, electrical line to alternator terminal B+	M6	Nm	8
		M8	Nm	10

 Engine mounts, engine supports

Number	Designation			Engine 926.969
BA22.10-N-1010-01M	Screw/bolt, engine support to engine mount	M14	Nm	–
		M16	Nm	260