L01.10-0002-09
1 Engine
2 Charge air pipe (charge air manifold)
3 Screw/bolt
4 Seal
5 Air intake hose
6 Charge air pipe
7 Clip
8 Screw/bolt
9 Engine mount
10 Wiring harness (alternator)
11 Screw/bolt
12 Securing clamp
13 Ground cables
14 Compressed-air line (engine brake cylinder)
15 Screw/bolt
16 Clip
17 Exhaust pipe
18 Gearshift lever
19 Seal
20 Hexagon socket head screw
G2 Alternator
M1 Starter
D01.10-0052-09
1 Engine
8 Screw/bolt
9 Engine mount
22 Plug connection (neutral position switch)
23 Plug connection (reverse lamp switch)
24 Connection (tachometer sensor)
25 Propeller shaft
26 Screw/bolt
27 Nut
28 Clutch slave cylinder
29 Screw/bolt
30 Plug connection for vehicle wiring harness (PLD control unit)
31 Fuel line (manual fuel feed pump)
32 Fuel line (fuel filter)
33 Vacuum line
34 Power steering pump
35 Allen head bolts
36 Cross plate
37 Coolant hose
38 Coolant hose
39 Engine supporting arm
A6 PLD control unit
Modification notes
Tightening torques for transmission on engine - added | Operation step 30 | ||
2.4.07 | Fitting, compressed air line to compressor |
| Remove/install | ||
Installation | Replace all self-locking nuts and bolts | ||
1 | Switch off ignition | ||
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. | |
2 | Disconnect the battery | ||
| Notes on battery | All models | |
3 | Remove service cover | ||
4.1 | Remove forked crossmember | Does not apply to AWD vehicles | |
4.2 | Remove front engine support | AWD vehicles | |
4.3 | Remove engine crossmember at rear | AWD vehicles | |
5 | Remove soundproofing panels on oil pan and transmission | Engine 904.904/908 up to 049131 Installation: Quick-release fittings must latch. | |
6 | Remove radiator | ||
7 | Remove air intake hose (5) and charge air pipe (2) | ||
8 | Remove charge air pipe (6) | ||
9 | Remove coupling jaw crossmember | ||
10 | Detach coolant hose (38) at coolant pump | ||
11 | Detach coolant hose (37) at connection piece of coolant pump | ||
12 | Disconnect ground cables (13) at timing case | ||
13 | Detach compressed air line (14) from engine brake cylinder | Engines fitted with engine brake. | |
14 | Remove starter (M1) | ||
15 | Disconnect wiring harness (10) at alternator (G2) with connection | ||
16 | Disconnect plug connection for vehicle wiring harness (30) at PLD control unit (A6) | ||
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. Wear protective clothing when handling fuel. | |
17 | Disconnect fuel line (31) at fuel priming pump and fuel line (32) at the fuel filter | Collect escaping fuel. | |
18 | Disconnect pressure line for constant throttle | Engines fitted with constant throttle. | |
19.1 | Detach vacuum line (33) at vacuum pump | Engines fitted with vacuum pump | |
| |||
19.2 | Disconnect lines from compressor | Engines fitted with compressor | |
Connection, compressed air line to compressor. | |||
Connection, inlet line to compressor. | |||
20 | Detach power steering pump (34) at vacuum pump or compressor | Do not separate hydraulic oil lines. Tie up power steering pump to the side if necessary. | |
| |||
21 | Disconnect plug connection (23) at reversing lamp switch | ||
22 | Disconnect plug connection (22) at neutral position switch | ||
23 | Take off tachometer sensor connection (24) at transmission | Installation: Replace sealing. | |
24 | Detach clutch slave cylinder (28) at transmission | ||
| |||
25 | Take off propeller shaft (25) at transmission | ||
| |||
26 | Remove exhaust pipe (17) | ||
27 | Take off shift lever (18) | ||
28 | Detach transmission bearing bracket at transmission; unscrew bolts (15) for this step | ||
| |||
29 | Remove engine (1) together with engine supporting arm (39) | ||
Shackle, DIN 82101 | |||
Engine supporting arm | |||
30 | Disconnect engine (1) from transmission | Place down engine and transmission securely after lifting out. | |
With transmission 710.640 | |||
With transmission 715.051 | |||
31 | Install in the reverse order | ||
32 | Re-teach in transponder keys (also replacement keys) | Only if a reconditioned engine or a new MR/PLD control unit is fitted. | |
33 | Inspect engine oil level and adjust to correct level if necessary | See owner's manual | |
34 | Check coolant level and adjust to correct level, if necessary | ||
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. | |
35 | Start engine | Do not rev up engine as long as no oil pressure is indicated. | |
The oil pressure gage must indicate oil pressure after about 10 seconds. | |||
36 | Turn off engine | ||
37 | Check engine, cooling system and steering hydraulics for leaks | Visual inspection. | |
38 | Set time on tachograph | ||
39 | Enter engine number in FDOK "Screen 1111" | Only if a reconditioned engine is installed. |
Check values for engine oil pressure
Number | Designation | Engines | ||
BE18.00-N-1001-01C | Engine oil pressure at | Idling speed | bar | 0.5 |
maximum speed | bar | 2.5 | ||
Compressor (compressed air system)
Number | Designation | Engines | ||
BA13.30-N-1007-01A | Fitting, compressed air line to compressor | Nm | 90 | |
BA13.30-N-1008-01A | Fitting, suction line to compressor | Nm | 100 | |
Clutch operating mechanism
Number | Designation | Engine | Engine | ||
BA25.20-N-1002-01E | Clutch slave cylinder on transmission | Nm | 25 | 25 | |
Manual transmission complete
Number | Designation | Trans-mission 710.640 | |
BA26.10-N-1001-01B | Transmission bearing bracket on transmission | Nm | 96 |
BA26.10-N-1003-01B | Transmission to engine | Nm | 50 |
Complete manual transmission
Propeller shaft
Number | Designation | Model | Model | ||
BA41.10-N-1001-01D | Propeller shaft on transmission | M101 | Nm | 62 | 62 |
M121.5 | Nm | - | 100 | ||
Vacuum pump
Number | Designation | Model | |
BA43.05-N-1002-01B | Vacuum line on vacuum pump | Nm | 30 X |
Power steering pump
Referenced documents
- ah5410p000101a
- ah5410p000101a Notes on battery
- ap2000d2080a Replace coolant
- ar0110d240001d Removing and installing engine with removal fixture
- ar0715d162801d Separate, connect plug connection of vehicle wiring harness at MR/PLD control module
- ar0910d8030d Remove/install air intake hose
- ar0941d1311d Remove/install charge air pipe
- ar1530d7100d Remove/install starter
- ar1540d503201d Separate, connect wiring harness at generator with tie
- ar2020d3865d Remove, install radiator
- ar2020d744002d Detach, attach coolant line at connection piece of coolant pump
- ar2020d744003d Detach, attach coolant line at coolant pump
- ar2210l1170a Remove/install rear engine cross member
- ar2210l4320a Remove/install front end supports
- ar2520d015001d Detach, attach slave cylinder at transmission
- ar2610d002001d Detach, attach transmission bearing bracket at transmission
- ar2619d000101d Separate, connect plug connection at reversing light switch
- ar2619d000103d Separate, connect plug connection at neutral position switch
- ar2619d000104d Detach, attach speedometer sensor connection at transmission
- ar2660d061011d Detaching and attaching shift lever
- ar3100d1000d Remove, install coupling jaw cross member
- ar3100d1100d Remove, install forked crossmember
- ar4110d005014d Detach, attach propeller shaft at transmission
- ar4630d050002d Detaching and attaching power steering pump
- ar4910d714001d Remove front exhaust system
- ar8057l0010a Programming transponder keys
- as0000z000501a 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.
- as4700z000101a 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.
- as5410z000101a Risk of fire/risk of explosion due to short circuit and escaping oxyhydrogen gas. Risk of (burn) injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte/mist, short circuit and arcing. Risk of