Remove/install engine

AR01.10-D-2400H

Remove/install engine

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

Disconnect ground cable and positive cable of battery

2

Remove bottom section of soundproofing

AR94.30-D-5300A

3

Remove heat shield

AR49.00-D-1000-01A

4

Remove engine hood

AR88.40-D-3000A

5

Remove front grille

AR88.00-D-2115B

6

Remove front end cross member

AR88.00-D-2302A

7

Remove front bumper

AR88.20-D-2000C

8

Remove radiator

AR20.20-D-3865G

9

Detach / attach coolant hoses and lines on engine

AR20.20-D-3865-06A

10

Remove air intake hose

AR09.10-D-8030F

11

Extract steering gear oil from power steering pump



*210589007100

12

Detach high pressure hose at power steering pump and place to the side



*BA46.30-N-1003-01A

13

Detach vacuum lines at intake manifold

AR09.20-D-1310-06B



*BA09.20-N-1004-02A

14

Remove idle speed control (ISC) actuator

AR30.22-D-1152B

15

Detach intermediate flange at intake manifold

AR09.20-D-1310-08C



*BA09.20-N-1002-02A

16

Remove air pump switchover valve

AR14.30-D-7255A

17

Remove purge control valve

AR47.30-D-8220A

18

Take off common bracket of purge control and air pump switchover valves at intake manifold

 The brackets are an obstruction when fitting on the engine removal fixture.

19

Detach cover at ventilation housing

AR83.10-D-0010-01C

20

Disconnect engine wiring harness on vehicle side

AR15.18-D-1000-02B

 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

Disconnect fuel lines at engine

AR47.25-D-1000-01C

22

Detach exhaust system at exhaust manifold

AR49.10-D-7140-03C



*BA49.10-N-1001-01A

23

Detach shift cables at transmission, attach

AR26.60-D-6627-01A

24

Detach electric wiring harness at transmission

AR26.19-D-0001-05A



*BA26.10-N-1001-01A



*BA26.19-N-1001-01B

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

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

25

Detach hydraulic line of central release

AR25.20-D-2000-01A



*000589403700



Brake fluid notes

All models

AH42.50-P-0001-01A

26

Detach power take-off connections

Transmission 722.620 with code N05 or N07

AR26.45-D-0010-04A



*BA26.45-N-1003-01A



*BA26.45-N-1004-01A



*BA41.20-N-1001-01A

27

Detach propeller shaft at transmission

AR41.10-D-0050-14C



*BA41.10-N-1001-01B



Notes on installing propeller shaft

Model 901, 902, 903, 904

AH41.10-N-0001-01A

28

Remove engine crossmember at rear

AR22.10-D-1170A

29

Remove engine with removal fixture

AR01.10-D-2400-01C



*BA22.10-N-1002-01H

30

Install in the reverse order

31

Bleed clutch operating system

AR25.20-D-0070A

 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

32

Inspect engine and cooling system for leaks

 Run engine until warm, switch off and inspect for leaks.

33

Inspect fuel system for leaks

 Run engine, switch off and inspect for leaks.

34

Set time on instrument cluster

if code J19 fitted

35

Set time on stationary heater timer

if code H11 or H86 fitted

36

Code radio

Number

Designation

Engine 111.979/
984

BA09.20-N-1002-02A

Intermediate flange on intake manifold

M8

Nm

21

BA09.20-N-1004-02A

Vacuum line to vacuum connection of intake manifold

Nm

30

Number

Designation

Engine 111.984

BA22.10-N-1002-01H

Engine support on front end mount

Nm

83

Number

Designation

Transmission 711.605

Transmission 711.620/
621

BA26.10-N-1001-01A

Bolt connecting manual transmission to engine

Nm

38

38

Number

Designation

Trans-mission
711.605/
620/621

BA26.19-N-1001-01B

Bolt, speedometer sensor to transmission

Nm

10

Number

Designation

PTO 28-2b with output flange code N07 with
transmissions 711.620/621

PTO 28-2c without output flange code N05 with
transmissions 711.620/621

BA26.45-N-1003-01A

Slave cylinder on power takeoff

Nm

13

13

BA26.45-N-1004-01A

PTO hydraulic line bracket to transmission housing

Nm

38

38

Number

Designation

Model
690.6, 901, 902, 903, 904, 905 except Minibus Sprinter Low Floor

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Screw headE18

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

PTO 28-2b (with output flange code N07) with transmission 711.620 in model 901.6, 902.6, 903.6, 904.6

BA41.20-N-1001-01A

Propeller shaft to PTO

Stage 1

Nm

23

Stage 2

°

-

Number

Designation

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

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

–

VDA pump

Nm

38

VT pump

Nm

-

Number

Designation

Engine
111.979/
984

BA49.10-N-1001-01A

Flange connection for front exhaust system - exhaust manifold

Nm

23