Remove/install engine

AR01.10-P-2400GH

Remove/install engine

15.2.12

 

Remove/install

1

Open engine hood and move to vertical position

AR88.40-P-1000GG

2

Switch off ignition

 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

3

Disconnect ground cable from battery

AR54.10-P-0003G



Notes on battery

All models

AH54.10-P-0001-01A

4

Disconnect engine wiring harness

AR01.00-P-2410GH

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



Notes on coolant

All engines

AH20.00-N-2080-01A

5

Remove radiator

AR20.20-P-3865GH

6

Attach guard plate for condenser (4)

if A/C fitted (code H02)



Guard plate for radiator/condenser

WF58.50-P-0110-01A

7

Remove poly-V belt

AR13.22-P-1202HA

8

Loosen vent lines (8) from bracket

9

Detach hose line (6) of boost pressure control from intake manifold (5)

10

Detach vacuum line (7) from vacuum pump



*BA43.05-P-1004-01B

11

Detach vacuum hose (14) from exhaust gas recirculation vacuum unit

12

Remove intake hose (9)

 Remove with crankcase ventilation hose

13

Detach charge air hose (13) from heat exchanger (12)

14

Detach charge air hose (11) from heat exchanger (12)

15

Detach front exhaust pipe at turbocharger (15)



*BA09.40-P-1001-01A

16

Unscrew bracket (16) of front exhaust pipe at transmission

17

Unscrew transmission on the frame side

 Transmission is taken out with engine, see reference: Remove transmission;
only carry out steps 6 - 17.

Operation step 14: detach stabilizer bar only from transmission

AR27.10-P-0500G

18

Unscrew power steering pump (1) with connected lines



Secure power steering pump to body.

*BA46.30-P-1003-01B

19.1

Unscrew air conditioner compressor (2) with connected lines

 To do this, detach connector at air conditioner compressor and attach air conditioner compressor to body.

Only with code H02

20

Detach coolant hose for stationary/auxiliary heating on the engine side

21

Detach coolant hose (4) for heat exchanger on the engine side

 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

22

Detach fuel lines from engine



 Open tank lock.

Seal fuel lines with clamps

*000589403700

23

Unscrew mounting screws of engine mount on the frame

AR22.10-P-1260GH

24

Take out engine with transmission

Load regulator
gotis://H_00.12_04.0

25

Install in the reverse order

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

26

Check for leaks with engine running

AR27.00-P-0100A

27

Inspect cooling system for leaks

AR20.00-P-1010HA

28

Read out fault memory and erase

Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed.

Engine Diagnosis Manual: Register 0: Connecting and Using Test equipment.

Number

Designation

Engine
602.983

BA09.40-P-1001-01A

Screw/bolt, flange connection of turbocharger/front exhaust pipe

Nm

25

Number

Designation

Model 461, 463

BA43.05-P-1004-01B

Vacuum line on vacuum pump

Nm

30

Number

Designation

Model 461.321/
322/323/326/
327/328/329/
335/336/337/
338/341/365/
366/367/368

BA46.30-P-1003-01B

Screw/bolt, power steering pump to support

Nm

20