Remove/install engine

AR01.10-D-2400F

Remove/install engine

08.10.2019

Engine

611.981/987 in model 901.6, 902.6, 903.6, 904.6

Engine

611.983 in model 690.6

1

Heater feed coolant hose

2

Front exhaust part

3

Bracket

4

Heater return coolant hose

5

Return flow pipe

6

High pressure pipe

7

Sealing ring

8

Vacuum line

9

Air intake hose

10

Fuel line

11

Fuel line

12

Vacuum line

13

Refrigerant line

14

Sealing ring

15

Screw

16

Propeller shaft

17

Nut

18

Tachograph sensor

19

Sealing ring

20

Backup light switch plug and engine start/stop switch

21

Rear engine support

22

Nut

23

Nut

24

Shift cable

25

Shift cable

26

Ground cable

27

Clutch line

28

Fuse

29

Sealing ring

30

Screw

31

Engine mount

32

Engine removal device

 

Remove/install

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from 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

1

Drain air conditioning system

Engine 611.981/987 in model 901.6, 902.6, 903.6, 904.6
with code H06 (Air-conditioning system)

AR83.30-D-1780A

Engine 611.981/987 in model 904.6
with code HK1 (Regulated air conditioning, roof equipment)
Engine 611.983 in model 690.6
with code HH6 (Air conditioning, roof equipment)

AR83.30-A-1780B

2

Remove engine hood

Remove/install engine hood

AR88.40-D-3000A

3

Disconnect engine wiring harness on vehicle side

Disconnect, connect engine wiring harness at vehicle side

AR15.18-D-1000-02A

 Do not disconnect engine wiring harness from starter

4

Drain off coolant

Drain/pour in coolant

AR20.00-D-1142A

 On the cooler

5

Remove complete cooler unit

Remove/install radiator

AR20.20-D-3865F

6

Remove charge air manifold upper part

Remove/install top section of charge air distribution pipe

AR09.41-D-1312A

 Seal ducts

7

Remove high-pressure line (6) and return line (5) from the power-steering pump

 Installation: Install new sealing ring (7)

 High pressure expansion hose to power steering pump

*BA46.30-N-1003-01A

8

Unclip fuel lines (10, 11) and remove from the fuel housing

 Installation: Install new clamps

9

Remove refrigerant line (13) from A/C compressor

 For vehicles with air conditioning (code HH9)

 Installation: Replace sealing ring (14)

10

Remove vacuum line (8) for brake booster from the vacuum pump

 Quick-release fastener (press together notches and detach)

11.1

Unhook heater return coolant hose (4) and disconnect quick-release fastener

Engine 611.981/987 in model 901.6, 902.6, 903.6, 904.6
with code HH6 (Air conditioning, roof equipment)
with code HH9 (Air conditioner, automatic heater control)

 Quick-release fastener (press together notches and disconnect)

11.2

Remove heater return coolant hose (4) from the circulation pump

Engine 611.983 in model 690.6
with code HH6 (Air conditioning, roof equipment)
with code HH9 (Air conditioner, automatic heater control)

 For vehicles 690.6 with air conditioning (code HH6/HH9)

12

Remove heater feed coolant hose (1) from the side coolant pipe on the cylinder head

13

Remove air intake hose (9) from the air filter housing

14

Remove vacuum line (12) from the exhaust gas turbocharger vacuum cell

15

Remove nuts from the bracket (3) for the front exhaust part (2)

16

Remove front exhaust part (2) from the exhaust gas turbocharger

17

Remove propeller shaft (16) from the output flange

Topical note

Notes on installing propeller shaft

AH41.10-N-0001-01A

 Propeller shaft to transmission

*BA41.10-N-1001-01B

18

Remove tachograph sensor (18) from the transmission

 Installation: Install new sealing ring (19)

19

Disconnect plug (20) from the backup light switch and engine start/stop switch

20

Unhook shift cables (24, 25); to do this, press the shackles, unhook from the bracket, and unclip shift cables from the ball heads

 Installation: Ensure that the shift cables (24, 25) are seated correctly on the ball heads

 Only for manual transmission G20, G32
For sprintshift transmission, disconnect connectors.

 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

21

Remove bracket of the clutch line (27) from the transmission, remove retainer (28), and pull clutch line (27) out of the clutch slave cylinder in the transmission

Topical note

Brake fluid notes

AH42.50-P-0001-01A

 Plug clutch line (27) with suitable stop plugs (brake caliper bleed valve plug)

 Install new retainer (28) and sealing ring (29)

22

Remove ground line (26) from the frame

23

Remove nut (22) bearing from transmission

 Bolt, rear engine mount to transmission

*BA22.10-N-1005-01L

24

Remove nuts (23), slowly lower rear engine carrier (21), and remove completely

 Transmission is on the front axle crossmember

 Nut/bolt, rear engine crossmember to mounting console

*BA22.10-N-1004-01L

25

Adjust engine removal device (32)

 Lock screw in the 4th notch (arrow) of the engine removal device (32)

26

Hook engine removal device (32) into the front and rear lifting lugs (arrows) on the cylinder head

27

Remove screws (30) of the engine carrier from the engine mount on both sides

 Bolt, engine support to front engine mount

*BA22.10-N-1002-01L

28

Carefully lift out engine with transmission

 Observe cable duct for alternator wiring harness, foam cover, air duct, and front bulkhead panel

29

Install in the reverse order

30

Bleed clutch operating system

Bleed clutch operating system

AR25.20-D-0070A

 Only for manual transmission G20, G32

31

Check cooling system for leaktightness

Inspect cooling system for leaks

AR20.00-D-1010C

32

Charge air conditioning system

AR83.30-D-1777A

33

Bleed low pressure fuel circuit

Bleed low pressure fuel circuit

AR07.16-D-0100A

 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

34

Check oil thickness

 Allow engine to warm up, switch off, and check leak tightness

 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

35

Inspect fuel system for leaks

 Allow engine to run, switch off, and check leak tightness

36

Code radio; set time

 Engine mounts, engine supports

Number

Designation

Engine 611.981/983/987

BA22.10-N-1002-01L

Bolt, engine support to front engine mount

Nm

83

 Engine mounts, engine supports

Number

Designation

Engine 611.981/983/987

BA22.10-N-1004-01L

Nut/bolt, rear engine crossmember to mounting console

Nm

45

 Engine mounts, engine supports

Number

Designation

Engine 611.981/983/987

BA22.10-N-1005-01L

Bolt, rear engine mount to transmission

Nm

89

 Propeller shaft

Number

Designation

Model 690.6, 901, 902, 905 (except 905.613)
Model 903.0/4/6, 904.0/4, 904.6 (except 904.663)
except code ZG1 (Engageable all-wheel drive)
except code ZG2 (Permanent all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Model 905.613
Except Sprinter low floor minibus

Model 903.6, 904.6 (except 904.663)
with code ZG1 (Engageable all-wheel drive)
Model 903.6, 904.6 (except 904.663)
with code ZG2 (Permanent all-wheel drive)
Model 903.6, 904.6 (except 904.663)
with code ZG3 (Engageable all-wheel drive with gear reduction)

BA41.10-N-1001-01B

Propeller shaft to transmission

M101

Stage 1

Nm

70

-

Stage 2

°

-

-

M121.5

Hexalobular bolt

Stage 1

Nm

-

-

Stage 2

°

-

-

Torx bolt E14

Stage 1

Nm

-

-

Stage 2

°

-

-

 Propeller shaft

Number

Designation

Model 904.663
Model 905.613
Sprinter low-floor minibus

BA41.10-N-1001-01B

Propeller shaft to transmission

M101

Stage 1

Nm

70

Stage 2

°

-

M121.5

Hexalobular bolt

Stage 1

Nm

-

Stage 2

°

-

Torx bolt E14

Stage 1

Nm

-

Stage 2

°

-

 Power steering pump

Number

Designation

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6, 909

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

–

VDA pump

Nm

38

VT pump

Nm

–