Detach/attach body from frame

AR60.80-P-1200GL

Detach/attach body from frame

15.06.2018

Model

461.302/304/305/331/332/333/334/340/342/344

Modification notes

11.07.2017

Schraube Kreuzgelenk an Lenkgetriebe

BA46.40-P-1002-04B

1

Vacuum line

3

Expansion reservoir

19

Vacuum line

2

Coolant hose

4

Coolant hose

20

Fitted bolt

6

Fuel hose

7

Refrigerant line bolted connection

12

Threaded connection

13

Rear lamp mount

14

Rear lamp wiring harness

8

Refrigerant line bolted connection

9

Hose clamp

10

Fuel hose

11

Vent line

21

Coolant line

18

Electrical connector

15

Ground cable

16

Fuse

17

Shift rod

X22/19

Transmission tunnel transmission wiring harness connector

A

Spacer washer

B

Front bearing mount

C

Center bearing mount

D

Rear bearing mount

 

Remove/install

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Caution

Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 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

AR54.10-P-0003GL

Topical note

Notes on battery

AH54.10-P-0001-01A

2

Remove engine hood

AR88.40-P-3000GR

3

Remove underride guard

4

Remove fluid reservoir

Vehicles with code (H02) Air conditioning

AR83.30-P-6520GM

5

Remove right front wheel well paneling

Model 461.302/331/332/342 with engine 612.966
Model 461.304/305/333/334/340/344 with engine 642

AR62.20-P-1223GL

6

Disconnect refrigerant line bolted connection (8) from firewall on right

Vehicles with code (H02) Air conditioning



Compressor oils (specification 362.0)

BB00.40-P-0362-00A

 Immediately close openings.

 Installation: Replace O-rings, moisten thread and O-rings with compressor oil.

 Separation point, pressure line to firewall

*BA83.30-P-1009-01C

7

Drain coolant

Model 461.304/334/344 with engine 642.975
Model 461.305/333/340 with engine 642.884

AR20.00-P-1142GX

8

Remove coolant line (21)

9

Remove left front wheel well paneling

Model 461.302/331/332/342 with engine 612.966
Model 461.304/305/333/334/340/344 with engine 642

AR62.20-P-1222GL

10

Disconnect engine wiring harness

Model 461.302/331/332/342

AR01.00-P-2410GL

Model 461.304/305/333/334/340/344

AR01.00-P-2410GX

11

Disconnect coolant hose (2) from fuel preheating system

12

Disconnect coolant hoses (4) from coolant line

13

Remove vacuum line (1) from brake booster

 Check rubber grommet for damage, replace if necessary.

 Installation: Coat rubber grommet with soapy water.

14

Disconnect refrigerant line bolted connection (7) from firewall on left

Vehicles with code (H02) Air conditioning



Compressor oils (specification 362.0)

BB00.40-P-0362-00A

 Immediately close openings.

 Installation: Replace O-rings, moisten thread and O-rings with compressor oil.

 Separation point, inlet line to firewall

*BA83.30-P-1008-01C

15

Remove vacuum lines (19) from solenoid valves on differential locks

 Mark location of vacuum lines (19).

16

Remove bracket from expansion reservoir (3) on differential lock actuation

 Fasten expansion reservoir (3) to engine with cable ties.

17

Disconnect electrical connectors (18) from main wiring harness

 Installation: Reclose plastic bag with cable ties and install with opening pointing downward. Replace all cable ties.

18

Remove fitted bolt (20) from upper universal joint of steering shaft and remove universal joint from splines

 Position steering straight before removing universal joint and mark position of universal joint.

 Bolt, universal joint to steering gear

*BA46.40-P-1002-04B

19

Remove fuel hoses (6)

 Installation: Replace collar clamps.

20

Remove hand brake cables

AR42.20-P-0545GG

 Remove hand brake cables from hand brake lever and pull through opening in body floor.

21

Disconnect transmission tunnel transmission wiring harness connector (X22/19) below electronic selector lever module

22

Remove retainer (16) and unhook shift rod (17)

Model 461.302/331/332/342

AR27.60-P-0980GL

Model 461.304/305/333/334/340/344

AR27.60-P-0980GM

 Installation: Adjust shift rod (17):


23

Remove ground line (15) from frame

24

Unscrew screws (12) on rear bumper corner at body.

 Unscrew on left and right.

25

Remove taillamps

Vehicles without code (E10) Stealth lighting circuit except model 461.331

Remove/install taillampModel 461.302/304/305/332/333/334/340/342/344
except code E10 (Blackout lighting without convoy light)

AR82.10-P-4905GX

Remove/install taillampModel 461.302/304/305/331/332/333/334/340/342/344
with code E10 (Blackout lighting without convoy light)

AR82.10-P-4905GL

 Vehicles with code (E10) Stealth light circuit

 Mark electrical lines.

26

Pull rear lamp wiring harness (14) through opening in body rear wall

27

Loosen hose clamps (9) and slide fuel hose (10) upward

28

Remove bleed lines (11)

 Close all openings on fuel tank.

29

Fasten headlamp range adjustment and all electrical lines on firewall


Do not kink, damage or disconnect lines on headlamp range adjustment.
Otherwise the headlamp range adjustment can be damaged and must be replaced.

30

Remove body mount bolts

AR60.80-P-0065-01GL

 Bolt, body to frame

*BA60.80-P-1002-01A

31

Slightly lift body from frame

AR00.60-P-1000G

 Lift body at rocker panel with vehicle lift support arm.



Check

32

Ensure that no connections are present between body and frame

33

Completely lift body from frame

 Installation: Check condition of body bearing buffers (5), replace if necessary.

34

Pull chassis forward below body

 Installation: Install centering drifts on spacer washers (A) of the four middle bearing mounts (C). Install short centering drifts on spacers (A) of the two rear bearing mounts (D).

 Alignment punch

*463589003100

 Alignment punch

*463589013100

35

Support and secure body

36

Install in the reverse order

37

Bleed brake system

AR42.10-P-0010GG

38

Check refrigerant and heating system for proper function



AP20.00-P-2050G

39

Fill steering system

AR46.20-P-0500-10F

 Power steering

*BF46.20-P-1001-01B

40

Check power steering oil level



AP46.00-P-4611G

41

Read out and erase fault memory



AD00.00-P-2000-04A

42

Check engine vehicle for proper function

 Drag link

Number

Designation

Model 460, 461
Model 463
up to model year 2019

BA46.40-P-1002-04B

Bolt, universal joint to steering gear

M8

Steel

Nm

35

Aluminum

Nm

32

 Cab, cab mounting

Number

Designation

Model 461

BA60.80-P-1002-01A

Bolt, body to frame

Nm

43

 Air conditioning

Number

Designation

Model 461

BA83.30-P-1008-01C

Separation point, inlet line to firewall

Nm

44

 Air conditioning

Number

Designation

Model 461

BA83.30-P-1009-01C

Separation point, pressure line to firewall

Nm

17

 Filling capacities for steering gear

Number

Designation

Model 461, 463

BF46.20-P-1001-01B

Power steering

Filling capacity for MB power steering fluid

Liter

1,0

Sheet

BB00.40-P-0236-03A