Remove/install engine with front axle carrier

AR01.10-P-2500GD

Remove/install engine with front axle carrier

10.11.11

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of lifting platform and position the four support plates at lifting platform support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A

1.1

Unscrew oil drain screw from oil pan at automatic transmission and drain ATF

Only on vehicles fitted with transmission 722.7.

 Installation: Replace sealing ring.



*BA27.10-P-1001-03A

2

Drain coolant at radiator and crankcase

AR20.00-P-1142GF

3

Disconnect battery ground line

AR54.10-P-0003A

4.1

Remove washer fluid reservoir

Only for vehicles with code (875) Heated windshield washer system.

5

Disconnect engine wiring harness

AR01.00-P-2410GD

6

Remove front bumper.

AR88.20-P-2000GC

7.1

Remove charge air cooler

Engine 668 only.940/942.

 Engine 668.941: a connection pipe is fitted in place of the charge air cooler.

AR09.41-P-6817GD

8

Remove air intake cowl (1) and air intake duct (2) from the vehicle

9

Detach vacuum line (3) at turbocharger and vacuum line (9) at EGR valve

10

Remove vacuum line (4) from boost pressure sensor

11

Disconnect vacuum line (5) for brake booster from vacuum pump

 Quick-release coupling.

Press together catches (arrows) and detach vacuum line (5).

12

Remove induction hose from turbocharger (12) from plenum chamber

 Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with 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

13

Detach fuel lines (6, 7) at fuel full-flow filter and seal with suitable plug

14

Detach coolant hoses (10, 11) at coolant thermostat

15

Detach coolant hose (8) at heating return flow

16

Detach coolant hoses (15, 50, 52) at coolant expansion reservoir (49)

17

Unlock striker on coolant expansion reservoir (49) (arrow) and remove coolant expansion reservoir (49)

18

Detach coolant hose (14) at bottom of radiator and at side of longitudinal member (arrow)

19.1

Detach oil lines (13) at oil cooler and seal with a suitable plug

Only on vehicles fitted with transmission 722.7.

 The oil cooler is integrated within the radiator.



*BA20.20-P-1002-01G

20

Detach steering coupling (27) at steering shaft (28), take off thrust piece (29)

 Installation: Replace self-locking collar nut (31) or nut bracket (51).



*BA46.10-P-1002-01C

21

Disconnect positive line (25) and control line (26) for power steering pump at left frame longitudinal member

22

Detach shift cables (21, 22) by turning locknuts counterclockwise, releasing them from the bracket and then unsnapping the shift cables from the ball joints

 Installation: Ensure that shift cables (21, 22) are securely attached to the ball heads.

23.1

Disconnect electrical connectors to turning angle sensors, expose electrical line and place to one side

Only on models fitted with automatic clutch system (code 421)

 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

24

Open fixture (19), remove locking element (20) and pull clutch line (18) out of the hydraulic central clutch release bearing

 Seal clutch line (18) with a suitable plug.

 Installation: Replace fuse (20) and sealing ring.



Brake fluid notes

AH42.50-P-0001-01A

25

Detach suspension strut (37) at suspension strut dome

 Installation: Lead guide pin on suspension strut (37) into guides (arrow) on the suspension strut tower.



*BA32.25-P-1002-04A

26

Detach floating caliper (40) at steering knuckle, tie up in wheelhousing together with brake pads and connected brake hose

 Installation: Replace self-locking bolts (41).



*BA42.10-P-1001-10O

27

Disconnect plug connection for brake pad contact sensor (39) and plug connection for front axle speed sensor (38) in top of wheelhousing; expose cable

 The plug connection for brake bad contact sensor (39) is only installed at the front right.

28

Remove complete exhaust system

AR49.10-P-7000GD

29.1

Release the poly-V belt (47) and remove it from refrigerant compressor (A9)

Only on vehicles with code (580) Air conditioning or for USA Tempmatic

AR13.22-P-1202GF

30.1

Detach refrigerant compressor (A9) and attach it to the underbody with the connected refrigerant lines and electrical lines

Only on vehicles with code (580) Air conditioning or for USA Tempmatic

31

Prepare front axle carrier removal fixture (48)

 Risk of tipping during later lowering - note location of the adapter. Adapter modification required from model refinement package 03/2001 or VIN "WDB1680311J568590" .

Also from VIN "WDB1680311J568590"

Jack assembly adapter

gotis://A_25/35/49_03.0

32

Align front axle carrier removal fixture (48) at front axle carrier (32) and fit evenly

 Risk of tipping during later lowering.

Also from VIN "WDB1680311J568590"

33

Remove braces (34) on front subframe (32) and vehicle floor



*BA33.10-P-1003-01B

34

Take off wheelhousing liners on left and right at underfloor and fold down

 To gain access to the rear screw/bolts (33).

35

Unscrew screw/bolts (33) (8 pcs.)


 Installation: First fit all the Screw/bolts (33), then tighten.

*BA33.10-P-1001-01B

36

Carefully lower engine together with front axle carrier (32) far enough to gain access to starter (M1) and alternator (G2)

 Proceed with caution to avoid damaging coolant hoses, AC hoses and electrical wiring.

 Installation: Guide (arrow) on the front axle carrier (32) must be inserted in the bore in the longitudinal member.

37.1

Unhook shift cable (17) from shift linkage, remove bracket (23) from transmission and take out of support (arrow). Unlock plug (16) on transmission (arrow) and detach

Only on vehicles fitted with transmission 722.7.

38

Disconnect ground cable (44) together with fixture at oil pan

39

Remove starter wiring harness (43) on starter (M1)

 Terminal 50

*BA15.30-P-1002-01D

 Terminal 30

*BA15.30-P-1003-01D

40

Remove alternator wiring harness (42) on alternator (G2)

 On vehicles with liquid-cooled alternator (G2) terminal D+ is designed as a connector.

 Circuit D+

*BA15.40-P-1001-01C

 Circuit B+

*BA15.40-P-1002-01C

41

Carefully lower the engine with front axle carrier (32) fully

 Proceed with caution to avoid damaging coolant hoses, AC hoses and electrical wiring.

42

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 appropriate work clothes when carrying out work on the vehicle.

AS00.00-Z-0005-01A

43.1

Check oil level in automatic transmission; fill with oil if necessary

Only on vehicles fitted with transmission 722.7.

AR27.00-P-0101GC

44

Bleed clutch operating system

AR25.20-P-0070GC

45

Inspect cooling system for leaks

AR20.00-P-1010GF

Number

Designation

Engine
668.940 /
941/942

BA15.30-P-1002-01D

Cable to starter circuit 50

Nm

6

BA15.30-P-1003-01D

Cable to starter circuit 30

Nm

15

Number

Designation

Engine 668

BA15.40-P-1001-01C

Cable to alternator terminal D+

Nm

6

BA15.40-P-1002-01C

Cable on alternator terminal B+

Nm

18

Number

Designation

Engine 668.940/
941/942

BA20.20-P-1002-01G

Union nut, automatic transmission oil line to radiator

Nm

25

Number

Designation

Trans-mission 722.3

Trans-mission 722.4/5/7

BA27.10-P-1001-03A

Drain plug on transmission oil pan

Nm

14

22

Number

Designation

Model 168.006/
007/008/
009/031/
033/032/
035/109/
131/132/
133/135

BA32.25-P-1002-04A

screw/bolt, suspension strut to suspension strut dome

Nm

40

Number

Designation

Model 168

BA33.10-P-1001-01B

Screw/bolt, front-axle carrier to body

M 12

Nm

120

BA33.10-P-1003-01B

Strut bolt on front-axle carrier
and body

M 10

Nm

60

Number

Designation

Model
168

BA42.10-P-1001-10O

Self-locking bolt, brake caliper to steering knuckle

Nm

115

Number

Designation

Model 168

BA46.10-P-1002-01C

Screw/bolt, steering coupling to steering shaft

Nm

20