Remove/install engine

AR01.10-P-2400HD

Remove/install engine

10.11.11

 

Remove/install

1

Disconnect ground cable from battery

AR54.10-P-0003A

2

Remove bottom section of soundproofing

AR94.30-P-5300AB

3

Remove top charge air pipe (8) at front

4

Remove viscous fan.

AR20.40-P-5660HB

5

Remove top charge air pipe (5)

6

Remove engine trim panel (9)

7

Remove radiator crossmember (1)

8

Remove radiator (2)

AR20.20-P-3865HA

9

Remove poly-V belt (10)

if AC (code 580, 581) fitted

AR13.22-P-1202HA

10

Attach guard plate for radiator/condenser



Guard plate for radiator/condenser

if AC (code 580, 581) fitted

WF58.50-P-0110-01A

11

Disconnect engine wiring harness

AR01.00-P-2410HW

12

Remove intake hose (3)

13

Remove vacuum fittings (4) at the vacuum units for EGR, boost pressure and throttle valve control (arrows), clip on.

14

Detach vacuum fittings on vacuum pump.

15

Open tank lock

 Reduce and seal overpressure in fuel tank

16

Seal off fuel lines (6) and (7)

 Disconnect fuel lines (6, 7) with clamping device



*000589403700

17

Detach vacuum pipe at charge air manifold (arrow)

18

Detach coolant hoses (17, 18) at rear cylinder head and at coolant thermostat housing

6 mm socket hexagon on flexible shaft for hose clamps with worm drive

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

19

Loosen screw/bolts for power steering pump belt pulley (12)



*BA46.30-P-1001-01A

20

Detach power steering pump (12) with the pipe system connected.



*BA46.30-P-1008-01A

21

Unbolt AC compressor (13)

If AC (code 580, 581) fitted: Attach AC compressor at bottom in side of engine compartment with piping connected.

22

Drain coolant at crankcase

AR20.00-P-1142HW

23

Remove lower charge air hose (19)

24

Unscrew exhaust system (20) at turbocharger and transmission intermediate bearing

25

Unscrew front propeller shaft (16) to transmission

AR41.10-P-0050B

24

Push propeller shaft (16) backward

26

Unhinge parking shift lock (66) at transmission

 The park lock interlock must only be removed in selector lever position "P".

27

Remove rear engine support (15)

AR22.10-P-1160HA

28

Unhinge shift rods (14) at transmission

Manual transmission

AR26.10-P-0020A

Automatic transmission

ra27047220600x

29

Place slave cylinder (21) with line connected to one side, secure.

Models with manual transmission

30

Unscrew screw/bolts (22) of front engine mount

AR22.10-P-1260HA

31

Remove engine with removal fixture

AR01.10-P-2400-01A

Load regulator

gotis://H_00.12_04.0

Hook mount

Engine carrier arm

32

Install in the reverse order

33

Inspect cooling system for leaks

AR20.00-P-1010HA

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

34

Check for leaks with engine running

35

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed.

Diagnosis Manual Volume 1.1: Index 0: Connecting and using test equipment.

Number

Designation

Model 210.003/004/010/
015/017/020/025/035/
037/045/053/055/072/
210/215/217/225/235/
237/245/272/610/617

Model 210.061/062/063/
065/070/074/
081/082/083/
261/262/263/
265/270/274/
281/282/283/
663

BA46.30-P-1001-01A

Screw/bolt on belt pulley

Nm

30

-

BA46.30-P-1008-01A

Screw/bolt, power steering pump to support

Nm

25

25