Remove/install starter

AR15.30-S-7100CE

Remove/install starter

16.05.2019

Engine

608 in model 415

1

Starter

4

Line

7

Electrical line

2

Bracket

5

Nut

8

Electrical line

3

Electrical wiring harness

6

Screw

9

Bolts

 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

 Warning

Risk of injury. Skin or eye injuries may result when handling hot or glowing objects.

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

AS00.00-Z-0002-01A

 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

 

Remove/install

1

Remove ground line of battery.

AR54.10-S-0003C

2

Remove fan unit.

AR20.40-S-5050CE

3

Remove charge air cooler.

AR09.41-S-0105CE

4

Remove electrical wiring harness (3) from bracket (2).

 Installation: Check retaining clips for damage.

If necessary,



Replace damaged retaining clips.

5

Remove line (4) from bracket (2).

 Installation: Check retaining clips for damage.

If necessary,



Replace damaged retaining clip.

6

Remove nut (5).

 Bolt/nut, lower holder for charge air cooler to crankcase

*BA09.41-N-1002-03CE

7

Remove holder (2).

 To do this, remove bolt (6).

 Bolt/nut, lower holder for charge air cooler to crankcase

*BA09.41-N-1002-03CE

8

Remove electric lines (7, 8).

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

 For this purpose, remove nuts.

 Nut, supply line to starter

*BA15.30-N-1002-01S

 Nut, control line to starter

*BA15.30-N-1003-01S

9

Remove starter (1).

 To do this, remove screw/bolts (9) .

 Bolt, starter to transmission housing

*BA15.30-N-1001-01S



Check

10

Check pinion of starter (1) for damage and wear.

When reusing the starter (1).

Depending on the findings,



Replace starter (1).

11

Check ring gear at flywheel for damage and wear.

 For this purpose, crank engine at center bolt of crankshaft in direction of engine rotation.

In case of corresponding findings



Replace flywheel.

AR03.30-S-8002CD

12

Install in the reverse order.



Check

 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

13

Perform engine test run.

 Charge air cooler

Number

Designation

Engine 608 in model 415

BA09.41-N-1002-03CE

Bolt/nut, lower holder for charge air cooler to crankcase

Nm

21

 Starter

Number

Designation

Engine 608 in model 415

BA15.30-N-1001-01S

Bolt, starter to transmission housing

Nm

39

 Starter

Number

Designation

Engine 608 in model 415

BA15.30-N-1002-01S

Nut, supply line to starter

Nm

17

 Starter

Number

Designation

Engine 608 in model 415

BA15.30-N-1003-01S

Nut, control line to starter

Nm

5