Remove/install engine

AR01.10-S-2400PS

Remove/install engine

10.07.2019

Engine

642 in model 470, 471

Modification notes

10.07.2019

Engine oil

BF18.00-N-1001-01PS

1

Power steering pump

3

Nut

2

Bolts

4

Engine mount

 Danger

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

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

AS00.00-Z-0010-01A

 Caution

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts

Always wear protective gloves when working on or near sharp and non-deburred vehicle parts.
Deburr repair panels.

AS00.00-Z-0017-01A

Note on calculation of tightening torque when using insertion or socket tools with various effective lengths

AH00.00-P-0015-01CW

Use of engine no. when installing reconditioned engines and factory-new replacement engines or crankcases

AH01.10-P-0001-01A

 

Remove/install

1

Remove hood.

AR88.40-S-3000P

2

Discharge air conditioning system.

AR83.30-S-1760P

3

Drain off coolant.

AR20.00-S-1142PS

4

Remove battery .

AR54.10-S-0005P

5

Remove the transmission with torque converter.

AR27.10-S-0500PS

6

Secure the electrical wiring harness of the transmission with torque converter to the engine with a cable tie.

7

Remove radiator unit.

AR20.20-S-3871PS

8

Remove diesel injection system control unit.

AR07.08-S-7009PS

9

Remove left air filter housing and right air filter housing.

AR09.10-S-1150PS

10

Disconnect engine wiring harness.

AR15.18-S-1000-05PS

Topical note

Information on preventing damage to electronic components due to electrostatic discharge

AH54.00-P-0001-01A

 Nut, electric line to prefuse box

*BA54.10-N-1003-01P

 Screw/bolt, alternator to crankcase

*BA15.40-N-1002-01PS

 M8

*BA00.10-N-1003-01A

 M6

*BA00.10-N-1002-01A

11

Remove the power steering pump (1) and secure it with a cable tie to the connected lines in the area around the wheel arch.

AR46.30-S-0500PS

 WIS Service Media
wsm://04_201800_42

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

 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

 Caution

Risk of injury to skin and eyes due to handling of engine oil. Risk of poisoning caused by swallowing engine oil

Wear protective gloves, protective clothing and safety glasses.
Do not fill engine oil into beverage containers.

AS18.00-Z-0001-01A

12

Remove the lines and hoses.

AR01.10-S-2400-15PS

Topical note

Notes on avoiding damage through contamination and foreign objects

AH00.00-P-5000-01A

Open and close coupling

AR09.41-D-1311-01WE



Compressor oils (specification 362.1)

BB00.40-P-0362-01A

 Bolt, thermostat to bracket

*BA27.55-N-1004-01PS

 Screw, line bracket

*BA27.55-N-1005-01PS

 Bolt, refrigerant line to refrigerant compressor

*BA83.30-N-1002-01P

 Pliers for click clamps

*171589003700

 Hose clamp pliers

*454589003700

 Assembly tool

*000589936300

 Record plug

*129589009100

 Set of protective covers

*001589019100

13

Remove the rear holder on the engine cover.

AR09.40-S-6045PS

14

Unscrew the screws (2) and nuts (3) on the engine mounts (4).

 Installation: Check the correct installation location of the engine mount (4), then screw the screws (2) and nuts (3) tight.

 Bolt, engine mount to frame-type integral support

*BA22.10-N-1003-01PD

 Nut, engine mount to side engine support

*BA22.10-N-1002-01PD

15

Remove engine.

AR01.10-S-2400-01PS

 Commercially available devices/tools
Engine crane

 Support plate

*906589016200

16

Attach engine to assembly stand.

If additional jobs have been performed on the engine.



000 588 00 31 00 Assembly stand for cars

WS01.00-N-3028B



Clean

17

Clean the contact surfaces of the engine mount (4).



Check

18

Check the engine mount (4) for wear and damage.

If there is a problem with these,



replace the engine mount (4) in question.

19

Install in the reverse order



Check

20

Check the engine oil level using the oil dipstick; correct it if necessary.


The engine oil level must not lie above the maximum marking.
Engine damage can occur otherwise.

 Engine oil

*BF18.00-N-1001-01PS

 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

21

Perform engine test run. While doing so, check engine for proper operation and leak tightness.

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

9

13

Phosphated

Nm

9

12

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1002-01A

M6

Galvanized

Nm

16

Phosphated

Nm

14

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

8.8

10.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

23

32

Phosphated

Nm

21

29

 Headless screws/bolts: screws/bolts and nuts, coarse-pitch thread

Number

Designation

12.9

BA00.10-N-1003-01A

M8

Galvanized

Nm

38

Phosphated

Nm

36

 Alternator

Number

Designation

Engine 642 in model 470, 471

BA15.40-N-1002-01PS

Screw/bolt, alternator to crankcase

Nm

20

 Engine mounts, engine supports

Number

Designation

Model 470, 471 with engine 642

BA22.10-N-1002-01PD

Nut, engine mount to side engine support

Nm

88

 Engine mounts, engine supports

Number

Designation

Model 470, 471 with engine 642

BA22.10-N-1003-01PD

Bolt, engine mount to frame-type integral support

Nm

88

 Transmission, oil cooling

Number

Designation

Transmission 722.9 in model 470, 471

BA27.55-N-1004-01PS

Bolt, thermostat to bracket

Nm

8

 Transmission, oil cooling

Number

Designation

Transmission 722.9 in model 470, 471

BA27.55-N-1005-01PS

Screw, line bracket

Nm

9

 Battery, voltage supply

Number

Designation

Model 471

Model 470

BA54.10-N-1003-01P

Nut, electric line to prefuse box

Nm

13

13

 Air conditioning

Number

Designation

Model 470, 471 with engine 642

BA83.30-N-1002-01P

Bolt, refrigerant line to refrigerant compressor

Nm

14

 Filling capacities for engine lubrication system

Number

Designation

Engine 642 in model 470, 471

BF18.00-N-1001-01PS

Engine oil

Filling capacity (oil and filter change)

Liter

8,5

Sheet

BB00.40-P-0228-51A

Sheet

BB00.40-P-0229-31A

Sheet

BB00.40-P-0229-51A

Sheet

BB00.40-P-0229-52A