Remove/install engine

AR01.10-T-2400CB

Remove/install engine

14.2.12

 

Remove/install

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

 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

1

Disconnect electric cables at battery

AR54.18-T-0002CB

2

Remove inner compartment flaps above the engine

3

Remove engine compartment flap

AR88.40-T-1100CB

4

Open all maintenance flaps on the tail

5

Close shutoff valves on heating system

 Location of shutoff valves, refer to operator's manual.

6

Drain coolant



Drain/fill in coolant

AP20.00-T-2080-01CB



*BF20.00-N-1001-01D



Notes on coolant

All engines

AH20.00-N-2080-01A

7

Remove fuel line (arrow) from fuel filter

8

Detach lower engine compartment paneling

AR61.20-T-1105CA

9

Remove crossmember (1) the back

AR61.10-T-6100C

10

Remove coolant hoses and the coolant lines accessible from above on the engine

AR20.20-T-3865-06CB

11

Remove alternator II (2)

Alternator II

AR15.40-T-5032CBA

12

Remove refrigerant compressor (3) from engine support (4)

 Attach refrigerant compressor (3) to the vehicle temporarily. Do not detach the lines.

 Owing to a risk of damage, do not strain the lines by extending or bending them.

13

Remove support arm for fan drive (5) from engine

 Ensure that propeller shaft on fan drive is completely pushed together after removal in order to exclude causing damage to the rubber bellows of the fan drive propeller shaft through pressure marks.

 The fan drive propeller shaft always lie on the guide tube or on the rubber bellows clamp.

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

Wear safety gloves, protective clothing and safety glasses, if necessary.

AS00.00-Z-0002-01A

14

Remove charge air pipe (6) of charge air manifold

AR09.41-T-8681-01CB



*BA09.41-N-1001-01H



*BA09.41-N-1002-01H



*001589752100



*000589642100

15

Remove engine supports (4)

 By removing belt tensioner (7) bracket. The engine support (4) obstructs smooth installation and removal of the engine.

16

Disconnect hose and line connections

AR01.10-T-2400-02CB

 Danger!

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

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

AS00.00-Z-0010-01A

17

Raise vehicle

 Only when a maintenance pit is not used.

AR00.60-T-1000B

18

Remove coolant hoses and the coolant lines accessible from below on the engine

AR20.20-T-3865-06CB

19

Remove power steering pump and place to one side

 Only perform the Operation steps to disassemble the power steering pump. Do not remove hydraulic pipe.

AR46.30-T-0500-02CB

20

Take off clutch booster

 Only carry out Operation steps for detaching the clutch booster from transmission (). Do not remove the hydraulic line and pneumatic line on the clutch booster. Tie clutch booster up to underbody.

AR25.20-T-0300CA

21

Remove plunger for operating release fork

 In this way, the release bearing slides out of the clutch release fork easily.

 Installation: Lock the release bearing .

Remove/install release mechanism

AR25.10-T-0050-03BA

22

Remove Screw/bolts on clutch housing below

 Remove bracket for lower engine cable set on clutch housing.

23

Support transmission

 Use a suitable piece of wood for support. It may also be necessary to use an inspection pit lift.

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

24

Place engine hoist on engine

 Use suitable pieces of wood for support.
 Owing to a risk of damage to the oil pan, do not support engine at the oil pan.

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

25

Remove Screw/bolts on clutch housing above

 Turn bracket with screw thread with the coupling housing to the side or possibly also disassemble.

26

Remove engine mount at the rear from vehicle frame

 The engine mounts are fixed in place with four Screw/bolts respectively on the vehicle frame.

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

27

Separate engine from transmission by pulling back

28

Remove release mechanism

AR25.10-T-0050-03BA

29

Install in the reverse order

30

Check coolant level



Correct engine cooling system liquid level Correct corrosion/anti-free protection

AP20.00-T-2010CA

Number

Designation

Engine
457.9

BA09.41-N-1001-01H

Clamp, charge air hose to charge air pipe

M5

Nm

8

M6

Nm

10

BA09.41-N-1002-01H

Screw/bolt, charge air pipe to charge air manifold

Nm

60

Number

Designation

Engines 402.970, 441.980, 446.938, 457.944

BF20.00-N-1001-01D

Filling capacity for coolant

without VOITH retarder

Liters

75 to 100

with VOITH retarder

Liters

95 to 120

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A