Remove/install engine with transmission

AR01.10-T-2401B

Remove/install engine with transmission

14.2.12

 

Remove/install

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnecting the battery

 First disconnect the negative terminal.

 To do this, unlock and pull out the battery tray.

2

Open liftgate

3

Remove engine compartment flap

AR88.40-T-1100B

4

Remove floor plate above transmission from inside of vehicle

5

Remove rear bumper

AR88.20-T-2200B

6

Remove rear crossmember

AR61.10-T-6100B

7

Raise vehicle

AR00.60-T-1000B

8

Detach lower engine compartment paneling

AR61.20-T-1105C

9

Detach cross strut below transmission from underbody

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

10

Drain coolant



Notes on coolant

All engines

AH20.00-N-2080-01A



Drain/fill in coolant

AP20.00-T-2080-01B

11

Drain oil from power steering

12

Drain engine oil



Engine oil and filter change

AP18.00-T-0101A

13

Disconnect return line on steering gear



- Open front flap

- Fold down center part of bumper

- Pull out spare tire.

 Catch escaping steering gear oil in a clean vessel.

14

Remove poly-V belt

AR13.22-T-1202B

15

Remove V-belt for air conditioning refrigerant compressor

AR13.21-T-0160B

 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

16

Disconnect hose and line connections

AR01.10-T-2400-02B

17

Detach propeller shaft from rear axle



*BA41.10-N-1002-01E

18

Detach shift rod from transmission

All except transmission 714.691 with EPS



*BA26.60-N-1004-01E

19

Detach compressed-air lines from shift cylinders on transmission

Transmission 714.691 with EPS

20

Unplug connectors from sensors from shift cylinders on transmission

Transmission 714.691 with EPS

21

Disconnect backup light switch plug, speedometer plug and starter lockout switch plug from transmission

22

Remove clutch booster

 Do not remove lines from clutch booster.

AR25.20-T-0300B

23

Detach electrical connections on alternator

24

Detach electrical connections on starter

25

Detach electrical connections on retarder

Transmission 714.100 with Voith retarder

 Electrical connections for retarder:

- Water temperature sensor connector

- Oil temperature sensor connector

- Proportioning valve connector

26

Remove reservoir compressed air line from proportioning valve for retarder

Transmission 714.100 with Voith retarder

 Depressurize system beforehand.

27

Remove positive and negative cable on substructure

28

Unhook accelerator linkage

29

Demount engine brake flap fitting from right turbocharger

Engine 402.970, 446.938 (V8-engines)

 In this way the exhaust system is separated from engine.



*BA09.40-N-1001-01H

30

Disconnect exhaust flexible pipe from left turbocharger

Engine 402.970, 446.938 (V8-engines)

AR49.10-T-7160B

 In this way the exhaust system is separated from engine.

31

Disconnect exhaust flexible pipe from turbocharger

Engine 441.980 (V6 engine)

AR49.10-T-7160B

 In this way the exhaust system is separated from engine.

32

Remove engine with removal fixture

AR01.10-T-2400-01B



*BA22.10-N-1001-01E



*000589642100

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

33

Install in the reverse order

34

Pour in engine oil



Engine oil and filter change

AP18.00-T-0101A

35

Pour in coolant



Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to correct concentration

AP20.00-T-2010A

36

Pour in oil for the power steering



Check and correct power steering fluid level

AP46.00-T-4611A

Number

Designation

Engine 402.970

Engine 441.980

Engine 446.938

BA09.40-N-1001-01H

Screw/bolt, engine brake flap fitting to turbocharger

Nm

50

50

50

Number

Designation

Engine 402.970/
446.938
in model
613.455/
485

Engine
441.980 in model
613.355

Engine 441.980
in model
613.364/
365

BA22.10-N-1001-01E

Screw/bolt, engine mount supporting bracket to side member

M12x1.5

Nm

70

70

70

Number

Designation

Trans-mission 714.100

Trans-mission 714.668

Trans-mission 714.690

BA26.60-N-1004-01E

Screw/bolt, shift rod to transmission

Nm

24

24

24

Number

Designation

Model 613.355/455/485

BA41.10-N-1002-01E

Screw/bolt, propeller shaft to rear axle

Nm

110