Remove/install engine · ar0110b2400a · Mercedes-Benz WIS

AR01.10-B-2400A

Remove/install engine

12.02.16

Cumbustion engine 457 with Vehicle 696

B01.10-0019-09

B01.10-0020-09

1 Hose of the charge air after-cooler (red)

2 Hose of the charge air after-cooler (black)

3 Air after-cooler retaining rod

4 Radiator upper hose

5 Radiator lower hose

6 Heating system hose

7 Heating system hose

8 Vehicle's electric wires

9 Starter electric wires

10 Starter motor fastening nut

11 Alternator electric wires

12 Exhaust pipe

13 Sealing gasket

14 Steering hydraulic tubes

15 Steering hydraulic tubes

16 Fuel line

17 Fuel line

18 Electric cables of the air conditioner's compressor

19 Air conditioner compressor tubes

20 Air conditioner compressor tubes

21 Engine brake pneumatic tubes

22 Top Brake pneumatic pipe

23 Air compressor's compressed air tubes

24 Gearbox oil tubes

25 Gearbox oil tubes

26 Fastening support of the tubes to the engine support

27 Fastening support of the tubes to the flywheel housing

28 Hydro-servo-pneumatic cylinder pneumatic tubes

29 Hydro-servo-pneumatic cylinder hydraulic tubes

30 Speedometer cable

31 Gearbox switches electric wires

32 Gearbox control pneumatic tubes

33 Bolts that fasten the transmission shaft to the flange

34 Transmission shaft

35 Bolts (supports of the engine to the mounts)

36 Front mounts

37 Bolts (gearbox supports to the mounts)

38 Rear mounts

39 Suspension handle (front one)

40 Gearbox supports

	Remove and install
1	Remove the vehicle's cabin.		AR60.80-B-1000E
2	Remove the hose between the turbocharger and the air filter.		AR09.10-B-8030B
3	Remove the expansion tank with the rack/support.		AR20.30-B-4950B
4	Remove the hoses (1/2) of the charge air after-cooler.	Install: Check the clamps and hoses (1/2) for condition, replace them if necessary. Do not swap the hoses.  The red hose (1) will have to be installed between the turbocharger and the after-cooler.
		 Indications for the assemblage of the air after-cooler.	AH09.41-B-0001-01A
			*BA09.41-B-1001-01B
5	Remove the contention rod from the air after-cooler (3).		AR09.41-B-6817-01A
6	Remove the water pump hoses, the upper (4) and the lower one (5).
7	Remove the heating system hoses (6/7)	Vehicles equipped with heating.
8	Disconnect the electric wires (8) from the control unit.		AR07.15-B-1628-01A
9	Disconnect the electric wires (9) from the starter motor.
10	Unfasten the nut (10), remove from the starter motor fastening stud, the ground cables and the wiring harness.		*BA15.30-B-1001-01H
11	Remove the fastening clamp and disconnect the electric wires (11) from the alternator.	Identify the electric wires to avoid assembly error.
12	Disconnect the exhaust tube (12).	Install: Clean the sealing surfaces. Replace the gasket (13).
			*BA14.10-B-1007-01B
13	Disconnect the power steering tubes (14/15).	Obstruct the tubes to avoid loss of lubricant oil. Collect the oil that flows off.
Danger!	Observe the safety measures when handling fuel.	Risks of explosion and injuries.	AS47.00-B-0001-01A
14	Disconnect the fuel tubes (16/17) from the motor.	Identify the tubes to avoid errors during the installation. Collect the fuel that flows off.
15	Disconnect the electric wires (18) and the tubes (19/20) from the air conditioner compressor.	Vehicles equipped with air conditioners.
16	Disconnect the tubes (21) of the engine brake and (22) Top Brake.
17	Disconnect the compressed air tubes (23).
18	Disconnect the oil tubes (24/25) from the gearbox and unfasten the fastening supports from the engine support (26) and flywheel housing (27).	Collect the oil that flows off. Install: Replace the sealing rings.
19	Disconnect the tubes (28) from the gearbox hydro-servo-pneumatic cylinder.	 De-pressurize totally the pneumatic system of the vehicle.
Danger!	Observe the safety measures when handling brake fluid.		AS42.50-B-0001-01A
20	Disconnect the tubes (29) from the gearbox hydro-servo-pneumatic cylinder.	 Collect the fluid in an appropriate recipient.
21	Disconnect from the gearbox the speedometer cable (30), the electric wires of the switches (31) and the pneumatic tubes (32).	Identify the electric wires to avoid assembly error.
22	Remove the bolts (33) and disconnect the transmission shaft (34) from the gearbox flange.	 Mark the position for later installation. Support it on a rack.  Transmission shaft with intermediate bearing: In order to disconnect it from the gearbox flange, it is necessary to unfasten the fastening bolts of the bearing at the cross bar, in order to make possible to move the shaft.
		 Transmission shaft to the flange.	*BA41.10-B-1003-01C
		 Intermediate bearing in the cross bar.	*BA41.40-B-1001-01A
23	Remove the bolts (35) from the engine supports to the front mounts (36).		*BA22.10-B-1001-01C
24	Remove the bolts (37) from the gearbox supports to the mounts (38).		*BA22.10-B-1003-01C
25	Support the engine by the front handle (39) and the rear supports (40).	 Use a steel cable or chain and an appropriate device.
26	Remove the engine from the vehicle.	 Lift the engine slowly, driving it carefully. Be careful, do not damage components, by mechanical shock, during engine removal. After having removed it, place it on a safe and appropriate place.
27	Remove the mounts (36/38).	 Check the condition, if necessary replace the mounts (36/38).
		 Front mounts fastening.	*BA22.10-B-1002-01C
		 Rear mounts fastening.	*BA22.10-B-1004-01C
28	Install in the reverse order
29	Bleeding the fuel system.	Operate the manual pump handle, until strong resistance is noticed.	AP47.00-B-1720-01D
30	Replenish and bleed the clutch actuation system		AR25.20-B-0070B
Danger!	Risk of personal and material damage when cranking the engine with the gearbox shifted in gear. Risk of injuries when working with the engine heated and operating.	Make sure that the gearbox is in neutral position. Use appropriate clothes and pay attention to the mobile an heated parts of the engine.	AS00.00-B-0005-01A
31	Run the engine	Do not actuate the starter continuously for more than 30 seconds If the engine does not start to operate within this interval, wait for approximately 1 minute to actuate it again.
32	Check the lubricant oil pressure with the engine in idle speed.	 Do not accelerate the engine until the oil pressure is shown in the indicator. The oil pressure will have to be reestablished in about 10 seconds.	*BE18.00-B-1001-01A
33	Check and if necessary replenish the power steering oil level.	The engine must be in idle speed rpm.	AP46.00-B-4611D
34	Stop the engine and check for eventual leaks.	 Check engine oil level, 5 minutes after engine shutdown.	AP18.00-B-0101I
35	Check the coolant level. Add if necessary.		AP20.00-B-2010C

Oil pressure

Número	Denominação			Engine 457.9; 460.984


BE18.00-B-1001-01A	Engine lubricating oil pressure, minimum permissible	idle speed rotation	bar	0.5
		full speed	bar	2.5

Charge air pipe/charge air cooling

Número	Denominação			Engine 457.90, 457.91, 457.93, 457.92; 460.984


BA09.41-B-1001-01B	Clamps attachment to the inlet and outlet flexibel hoses	M5	Nm	8
		M6	Nm	10

Exhaust manifold

Número	Denominação		Engine 460.984, 457.9 except 457.922/928


BA14.10-B-1007-01B	Exhaust pipe to exhaust manifold with engine-brake mechanism	Nm	50

Starter

Número	Denominação		Engine 457.9


BA15.30-B-1001-01H	Starter motor in the timing case	Nm	80

Engine mount, engine support

Número	Denominação			Engine 457.9


BA22.10-B-1001-01C	Engine fastening to front mount	M14x1.5	Nm	150
		M16x1.5	Nm	180
		M18x1.5	Nm	330
BA22.10-B-1002-01C	Fastening of engine front mount to support (mounting of engine mount)	M12x1.5	Nm	90
		M14x1.5	Nm	150
		M16x1.5	Nm	180
BA22.10-B-1003-01C	Engine attachment to rear engine mount	M14x1.5	Nm	150
		M18x1.5	Nm	330
BA22.10-B-1004-01C	Fastening of engine rear mount to support (mounting of engine mount)	M12x1.5	Nm	90
		M14x1.5	Nm	150
		M16x1.5	Nm	180

Propeller shaft

Número	Denominação				Chassis 382.0, 386.0, 386.3, 388.0, 693.0/1/2/3, 694.0, 695.0/3, 696.0/3


BA41.10-B-1003-01C	Propeller shaft attachment	Tapped holes terminals (clamps and screws)
			M10x1	Nm	65...80
			M12x1.25	Nm	115...135
			1/2"	Nm	160...180
		For flanges
			M10	Nm	70
			M12	Nm	125
			M14	Nm	185
			M16	Nm	275

Propeller shaft intermediate bearing

Número	Denominação			Vehicles 696


BA41.40-B-1001-01A	Transmission shaft's intermediate bearing bolt on cross member	M12x1.5	Nm	115

Referenced documents

ah0941b000101a Notes on the installation of charge air hoses downstream of the charge air cooler
ap1800b0101i Engine oil and oil filter change
ap2000b2010c Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to correct concentration
ap4600b4611d Check and correct power steering fluid level
ap4700b172001d Bleed fuel system
ar0715b162801a Separate, connect plug connection of vehicle wiring harness at MR/PLD control module
ar0910b8030b Remove/install air intake hose
ar0941b681701a Remove/install charge air cooler linkage
ar2030b4950b Remove/install expansion reservoir
ar2520b0070b Bleed clutch operating system
ar6080b1000e Remove/install cab
as0000b000501a 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.
as4250b000101a Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid
as4700b000101a 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.