Remove/install axle/engine subframe with engine

AR31.35-S-4200B

Remove/install axle/engine subframe with engine

10.11.11

 

Remove/install

1.1

Put vehicle into service mode.

 With code CL0 (air suspension)



Special instructions for lifting and supporting vehicle

Model 638

AH00.60-N-0100-01A

2

Disconnect ground line of battery

AR54.10-S-0005A



Notes on battery

All models

AH54.10-P-0001-01A

3.1

Drain air conditioning system

 Applies only to code H06 (air conditioning)

AR83.30-S-1760A

 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

4

Drain coolant

AP20.00-D-2080A

5

Remove bottom section of soundproofing

AR94.30-S-5300A

6

Remove front bumper (3)

AR88.20-S-2000A

7

Remove grill (2)

AR88.00-S-2115A

8

Remove lock crossmember (6)

AR88.00-S-2302A

9

Remove air filter housing (7).

AR09.10-S-1150B

10.1

Remove air intake line (8)

 With engine 601.942

11.1

Remove air intake pipe (9)

 With engine 601.970

AR09.41-S-8620A

12

Disconnect engine wiring harness

 Connecting point in leather bag.

AR01.00-S-2410B

13

Disconnect connectors on radiator

14

Detach coolant hose (13) at fitting (12)

 Check coolant hose (13) and clamp for condition, replace if necessary.

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

15

Unhook accelerator pedal cable (14) from bracket

AR30.10-S-3070-02B

16.1

Unhook Bowden cable pedal value sensor (15)

 with code G40 (automatic transmission)

AR30.10-S-3070-05A

17.1

Disconnect connector on backup light switch (S19)

 Without code G40 (automatic transmission)

18.1

Detach refrigerant lines (20) from expansion valve

 Applies only to code H06 (air conditioning)

 Installation: Install new sealing rings (19).



*BA83.30-N-1001-01A

19

Cut cable ties (arrows) on fuel lines (22, 25) and vacuum lines (23, 24)

 Replace cable ties.

20

Pull off vacuum lines (23, 24).

 Marking:
Key shutoff = BN/BU

Interior ventilation = BK

 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

21

Unlock and disconnect fuel lines (22, 25)

 Collect escaping fuel.

22.1

Detach shift cables from transmission.

 Without code G40 (automatic transmission)

AR26.60-S-6627-01A

22.2

Unhook shift cable from automatic transmission

 with code G40 (automatic transmission)

AR27.60-S-0100-01A

23

Remove front road wheels (32).

AR40.10-S-1100A

24

Remove heater air inlet

AR83.25-S-1401A

25

Unscrew threaded connection (67) of suspension strut

Use a box-end wrench to apply counterpressure to the shock absorber insert to prevent it from twisting when the nut is being loosened and tightened.



*BA32.25-N-1002-04A

26

Remove brake caliper (35)

 Do not stretch brake hoses.

AR42.10-S-0600A

 Attach brake caliper (35) to body using a suitable wire bracket.

27.1

Detach ABS sensors (B79) with shield (34) on left and right steering knuckle

 With code BB0 (ABS/ABD or ABS/ETS)

AR42.30-S-0150A

 Do not disconnect electrical connection

28

Remove bearing cup (48) and shackle (45) in left and right wheel arch

 Installation: Replace self-locking bolts (46, 47), do not mix up fish-plates (45). Observe installation position of fish-plates (40).



*BA31.35-N-1003-01A



*BA31.35-N-1004-01A

29.1

Disconnect connector (X106)

 with code G40 (automatic transmission)

30.1

Detach clutch slave cylinder (50) at transmission

 Without code G40 (automatic transmission)

 Do not disconnect hydraulic line.

31.1

Do not detach speedometer sensor (G4) or tachograph from transmission

 Do not disconnect electrical connection.

AR54.75-S-5360A

32

Mark position of steering gear shaft (53) and universal joint (52) using a suitable colored pencil

 Installation: Align color coding (arrow) of steering gear shaft (53) and universal joint (52). The steering remains centered!

33

Unscrew screw/bolt (51)

 Installation: Insert universal joint (52) on the steering gear shaft (53) until the bore in the universal joint (52) aligns with the radial groove in the steering gear shaft (53). Replace TORX bolt (51).



*BA46.10-N-1003-05A



*000589011000

34

Detach ground line from frame floor assembly

35

Remove front exhaust system (58) at exhaust manifold

 Installation: Assemble flange connection so that it aligns.

AR49.10-S-7140B



Assembly notes for exhaust systems with corrugated hose

Engine 111, 601 in model 638

AH49.10-N-0200-01A

36

Attach removal fixture (66) to axle/engine subframe (65)

 Align all terminal points.

Use a suitable strap to attach the front subframe and its ancillaries to the removal assembly.

Lifter mounting adapter
gotis://A_25/35/49_03.0

37

Remove front stop elements (55)

 Observe installation position.



*BA31.35-N-1002-01A

38

Lay engine wiring harness, vacuum lines, coolant hoses, cables and disassembled vehicle parts to one side, bind up together if necessary

 Unobstructed removal of the axle/engine subframe (65) must be guaranteed, do not damage components

39

Unscrew bolts (61, 63)



*BA31.35-N-1001-01A

40

Lower axle/engine subframe (65) downwards slowly

 Rotate the steering shaft to ensure that the steering gear shaft (53) slides on and off the universal joint (52)!
Ensure that adequate clearance to the exhaust system and removed vehicle parts is available!
 Installation: Align axle/engine subframe (65) so that bolts (61, 63) can be installed and the insertion of the steering gear shaft (53) in the universal joint (52) is guaranteed!

41

Install in the reverse order



Checking

42

Check for leaks, ensure that all fluids are at prescribed levels.

Number

Designation

Model Series 638 with Series 601.942/970 engine
without Code G40

BA26.10-N-1001-01F

Bolt, manual transmission to engine

Nm

55

Number

Designation

Model
638.014/034/
064/074/094/
114/134/164/ 174/194/214/ 234/244/274/294
without code G40

Model
638.014/034/
064/074/094/
114/134/164/ 174/194/214/ 234/244/274/294
with code G40

BA31.35-N-1001-01A

Axle/engine subframe on main vehicle frame

Nm

150

150

BA31.35-N-1002-01A

Front travel stop on frame

Nm

105

105

BA31.35-N-1003-01A

Bearing dish in fish-plate on frame

Nm

72

72

BA31.35-N-1004-01A

Bearing dish on front subframe

Nm

172

172

Number

Designation

Model
638

BA32.25-N-1002-04A

Nut, strut to body

Nm

66

Number

Designation

Steering 763.000 in model 638

Steering 763.000 in model series 638 with airbag

BA46.10-N-1003-05A

Universal joint to steering gear shaft
(TORX bolt)

Nm

24

24

Number

Designation

Model
638

BA83.30-N-1001-01A

Nut, suction and high pressure line to expansion valve

Nm

10