Remove/install engine with axle/engine subframe

AR01.10-S-2402A

Remove/install engine with axle/engine subframe

21.10.11

 

Remove/install



Special instructions for lifting and supporting vehicle

Model 638

AH00.60-N-0100-01A

1.1

Put vehicle into service mode.

 With code CL0 (air suspension)

2

Disconnect ground line of battery

AR54.10-S-0005A



Notes on battery

All models

AH54.10-P-0001-01A

3.1

Drain air conditioning system

 Applies only to code H06 (air conditioning)

AR83.30-S-1760A

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

4

Drain coolant

AR20.00-S-1142A

5

Remove front bumper

AR88.20-S-2000A

6

Remove front end cross member

AR88.00-S-2302A

7

Remove front grille

AR88.00-S-2115A

8

Remove air filter housing

AR09.10-S-1150D

9

Remove right headlamp

AR82.10-S-4720A

10

Remove air deflector shield

11

Remove front wheels

AR40.10-S-1100A

12.1

Remove additional reservoir from windshield washer reservoir

 With code F46 (headlamp cleaning system)

AR82.35-S-6000B

 The windshield washer reservoir remains installed.

13

Remove air inlet (55)

AR83.25-S-1401A

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

14

Mark off fuel lines (21, 22)

 Collect fuel which flows out.

AR47.25-P-1000-01A

15

Detach coolant hose (23) at AGR cooling module (24)

16

Remove coolant hose (4) on pulsed valve (Y37)

17

Detach vacuum lines (5, 6, 7)

18.1

Detach shift cables from transmission.

AR26.60-S-6627-01A

18.2

Unhook shift cable from automatic transmission

 with code G40 (automatic transmission)

AR27.60-S-0100-01A

19

Disconnect engine wiring harness

AR01.00-S-2410C

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

20.1

Remove retainer (10) for hydraulic line (11) on clutch slave cylinder and remove line

 Without code G40 (automatic transmission)

AR25.20-S-0070B

 Collect escaping brake fluid.

21

Remove drain pipe on windshield washer reservoir

22

Unscrew bolt (18) from bracket (19).

23.1

Remove refrigerant lines (16) on expansion valve

 Applies only to code H06 (air conditioning)

 Installation: install new O-rings (20).



*BA83.30-N-1001-01A

24

Unscrew bolt (25) on exhaust manifold (27)



*BA49.10-P-1008-01E

 Torx bit set

*000589011000

25

Remove exhaust system (26) completely

AR49.10-S-7000B

26

Remove boost pressure control pressure transducer (Y80) on axle/engine subframe (35) bracket

27

Detach vacuum line (3) on boost pressure control pressure transducer (Y80)

28

Remove brake caliper (30)

 Attach brake caliper on the body using a suitable wire.

AR42.10-S-0600A

29.1

Remove front acrylonitrile butadiene styrene sensors (B79)

 With code BB0 (ABS)

AR42.30-S-0150A

 Do not disconnect electrical connection.

30

Unscrew screw/bolt (46)

 Used a colored marker to identify the position of the steering gear shaft (48) and universal joint (47) (arrow).

 Installation: Align color coding (arrow) of steering gear shaft (48) and universal joint (47). The steering remains centered! Insert universal joint (47) in the steering gear shaft (48) until the bore in the universal joint (47) aligns with the radial groove in the steering gear shaft (48). Replace bolt (46)



*BA46.10-N-1003-05A

 Torx bit set

*000589011000

31

Remove bearing cup (42) and shackle (40) on right and left longitudinal member

 Installation: Replace self-locking Screw/bolts (41, 43). Install fish-plates (40) on correct sides.



*BA31.35-N-1003-01A



*BA31.35-N-1004-01A

32

Unscrew nut (36) on the left and right suspension struts (37)

 Use a box-end wrench to apply counterpressure to the shock absorber insert to prevent it from twisting when the nut (36) is being loosened and tightened.

 Installation: Replace self-locking nut.



*BA32.25-N-1002-04A

33

Position removal fixture under the axle/engine subframe (35)

 Align all terminal points.

Use a suitable strap to attach the front subframe and its ancillaries to the removal assembly.

Engine support device, engine hoist
gotis://A_01_09.0

34

Remove right engine support (39) and upper engine support (44)

AR22.10-S-1200A

35

Remove bolt (51) from left engine support (52)

AR22.10-S-1200A

36

Remove front stop element (54) on the axle/engine subframe (35)

 Pay attention to installation position of the front stop elements (54)!



*BA31.35-N-1002-01A

37

Lay engine wiring harness, vacuum lines, coolant hoses, cables and disassembled vehicle parts to one side, bind up together if necessary

 Unhindered extension of the axle/engine subframe must be achieved; do not damage components!

38

Unscrew Screw/bolts (56, 58)



*BA31.35-N-1001-01A

39

Remove engine with axle/engine subframe (35) slowly downwards

 Rotate steering shaft to ensure that the steering gear shaft (48) slides on and off the universal joint (47)!

Ensure unobstructed movement of the disassembled vehicle parts!

 Installation: Align axle/engine subframe (35) in such a way that Screw/bolts (56, 58) can be put in place and retraction of the steering gear shaft (48) in the universal joint (47) is achieved.

40

Install in the reverse order



Checking

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.
Always wear appropriate work clothing when working on the vehicle.

AS00.00-Z-0005-01A

41

Check for leaks with engine running

Number

Designation

Model
638.014/034/
064/074/094/
114/134/164/ 174/194/214/ 234/244/274/294
without code G40

Model
638.014/034/
064/074/094/
114/134/164/ 174/194/214/ 234/244/274/294
with code G40

BA31.35-N-1001-01A

Axle/engine subframe on main vehicle frame

Nm

150

150

BA31.35-N-1002-01A

Front travel stop on frame

Nm

105

105

BA31.35-N-1003-01A

Bearing dish in fish-plate on frame

Nm

72

72

BA31.35-N-1004-01A

Bearing dish on front subframe

Nm

172

172

Number

Designation

Model
638

BA32.25-N-1002-04A

Nut, strut to body

Nm

66

Number

Designation

Steering 763.000 in model 638

Steering 763.000 in model series 638 with airbag

BA46.10-N-1003-05A

Universal joint to steering gear shaft
(TORX bolt)

Nm

24

24

Number

Designation

Engine 611.980

BA49.10-P-1008-01E

Screw/bolt, flange connection to exhaust system

Nm

16.5

Number

Designation

Model
638

BA83.30-N-1001-01A

Nut, suction and high pressure line to expansion valve

Nm

10