Remove/install engine with axle/engine subframe

AR01.10-S-2402B

Remove/install engine with axle/engine subframe

21.10.11

 

Remove/install

1

Put vehicle into service mode.

 Only 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

Drain air conditioning system

 Only applies to code H06 (Air conditioning)

AR83.30-S-1760A

4

Take off front wheels

AR40.10-S-1100A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. 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

5

Drain coolant

AR20.00-S-1142A

6

Remove side protective covers on longitudinal member

7

Remove bottom protective cover on axle/engine subframe

8

Remove front end cross member

AR88.00-S-2302A

9

Remove front grille

AR88.00-S-2115A

10

Remove bumper

AR88.20-S-2000A

11

Remove suction air ducting from air filter housing

12

Remove headlamp on the right with flasher

AR82.10-S-4720A

13

Remove additional panes window wash water container

 Only with code F46 (headlamp cleaning system)

AR82.35-S-6000A

14

Remove air inlet heater

AR83.25-S-1401A

15

Remove air filter housing complete

AR09.10-S-1150C

16

Remove engine design cover

17

Unhook accelerator pedal cable (1) on throttle valve actuator control unit

 Expose accelerator pedal cable (1).

18

Detach shift cable at transmission

AR27.60-S-0100-01A

19

Disconnect engine wiring harness

AR01.00-S-2410D

20

Remove plug connection box (2)



*BA54.10-N-1005-01A

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

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury from bruises and burns if you hold your hands into engine when it is started or when 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

21

Disconnect hose and line connections

AR01.10-S-2400-02A



*BA83.30-N-1001-01A



*BA83.30-N-1002-01A

22

Remove exhaust system complete on the exhaust manifold

AR49.10-S-7000A

23

Unscrew bolt (8)

 Use a colored marker to identify the position of the steering transmission shaft (9) and universal joint (10) (arrow).

 Installation: Align color coding (arrow) of steering gear shaft (9) and universal joint (10). The steering remains centered! Insert universal joint (10) in the steering gear shaft (9) until the bore in the universal joint (10) aligns with the radial groove in the steering gear shaft (9). Replace bolt (8)



*BA46.10-N-1003-05A

 Torx bolt bits

*000589011000

24

Remove bearing cup (3) and shackle (4) on right and left longitudinal member

 Installation: Replace self-locking Screw/bolts (5). Pay attention to installation position of plate (4).



*BA31.35-N-1003-01A



*BA31.35-N-1004-01A

25

Remove brake caliper (7) on the right and left on the steering knuckle

 Do not damage brake lines. Brake lines remain attached.

AR42.10-S-0600A

 Attach brake caliper (6) on the body using a suitable wire.

26

Remove front acrylonitrile butadiene styrene sensors (B79)

 Only with code BB0 (ABS)

AR42.30-S-0150A

27

Unscrew threaded connections (11) on the left and right suspension struts (12)

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



*BA32.25-N-1002-04A

28

Position removal fixture under the axle/engine subframe

 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

29

Remove Screw/bolts (13) from right engine holder (14)



*BA22.10-N-1005-01G

30

Remove right engine holder (14) on longitudinal member



*BA22.10-N-1009-01G

31

Unscrew Screw/bolts (15) for left engine holding plate on longitudinal member



*BA22.10-N-1007-01G

32

Remove front stop element (16) on axle/engine subframe

 Pay attention to installation position of the stop elements (16)!



*BA31.35-N-1002-01A

33

Unscrew Screw/bolts (17) from axle/engine subframe



*BA31.35-N-1001-01A

34

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!

35

Move out engine with axle/engine subframe slowly downwards

 Rotate steering shaft to ensure that the steering gear shaft (9) slides on and off the universal joint (10)!

Ensure unobstructed movement of the disassembled vehicle parts!

 Installation: Align axle/engine subframe () in such a way that Screw/bolts (17, ) can be put in place and retraction of the steering gear shaft (9) in the universal joint (10) is achieved.

36

Install in the reverse order



Checking

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury from bruises and burns if you hold your hands into engine when it is started or when 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

37

Check for leaks with engine running

Number

Designation

Engine 104.900

BA22.10-N-1005-01G

Screw/bolt, engine holder on engine

Nm

53

BA22.10-N-1007-01G

Screw/bolt, retaining plate to body

Nm

58

BA22.10-N-1009-01G

Screw/bolt, engine holder on longitudinal member

Nm

58

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

Model 638

BA54.10-N-1005-01A

Nut, power supply cable to plug connection box

Nm

12

Number

Designation

Model
638

BA83.30-N-1001-01A

Nut, suction and high pressure line to expansion valve

Nm

10

BA83.30-N-1002-01A

Expansion valve bolt

Nm

8