Remove/install engine with transmission

AR01.10-D-2401SD

Remove/install engine with transmission

23.5.11

 

Remove/install

 Danger!

Risk of injury to skin or eyes caused by hydraulic fluid spraying out under high pressure. Risk of poisoning caused by swallowing hydraulic fluid

Depressurize hydraulic system completely before starting any work on system. Wear protective clothing and safety glasses.

AS00.00-Z-0013-01A

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A



Brake fluid notes

AH42.50-P-0001-01A

1

Lift/jack up vehicle

AR00.60-D-0100H

2

Remove engine hood

AR88.40-D-3000SD

3

Remove trim panel for cylinder head cover (1)

AR01.20-D-5015SD

4

Remove front module

AR88.30-D-1064SD

5

Disconnect electrical connector for engine wiring harness at the CDI control unit

AR07.08-D-7006SD

6

Disconnect electrical connectors from the glow output stage.

AR15.20-D-4330SD

7

Disconnect battery lines, loosen battery and push to one side, disconnect the positive line at the terminal and guide down and out of the battery box

AR54.10-D-0005SD

8

Disconnect engine wiring harness

AR54.15-D-9231-01SE

9

Detach pipe clamp (3) and remove seal cone

 Installation: Check seal cone and replace if necessary.



*BA14.40-N-1001-02D

 Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with 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

10

Remove hose clamps (4, 5) and pull out fuel hoses (6, 7)

 Collect fuel which flows out in a suitable container.

11

Detach coolant hose (2) at coolant pump

12

Detach refrigerant line (9) at refrigerant compressor

Only on vehicles with code (HH9) Regulated air conditioning (Tempmatic)

 Seal openings with suitable stop plug.



*BA83.30-N-1010-01F

13.1

Remove 2nd refrigerant compressor from carrier and hang up to the side with attached lines

Only for code (H08) Heavy duty air conditioning

AR83.55-D-5300SK

With code (N63) Engine power take-off wit carrier for additional A/C compressor

AR83.55-D-5300SL

13.2

Remove additional alternator from carrier and lay down to side with connected lines

With code (N62) Engine power take-off wit carrier for additional alternator

AR15.40-D-5032SK

14

Disconnect hydraulic line (8) at power steering pump and seal off openings

 Remember that hydraulic oil will leak out.



*BA46.30-N-1001-01M

 Set of stop plugs

*129589009100

15

Remove bracket (10)



*BA14.40-N-1006-02D



*BA14.40-N-1007-02D

16

Detach shift cables at transmission (11)

AR26.60-D-6626-01A

Long-life grease

*BR00.45-Z-1001-06A

17

Detach hydraulic hose (16) at central clutch release bearing (17) and seal off openings

 Remember that brake fluid will emerge.

 Set of stop plugs

*129589009100

18

Remove tamper-proof seal, unscrew bolt (12) and remove speed sensor (B6/12)

 Installation: Inspect O-ring, install new ring if necessary.

19

Remove rear engine crossmember (15)

AR22.10-D-1170SD

20

Remove propeller shaft (14) at transmission (11)

 Remove the bolts and securely tie up propeller shaft (14) outside the working area.



*BA41.10-N-1001-01B

21

Remove fan wheel (22) with viscous clutch



*BA20.40-N-1002-01N

 Counterholder

*611589004000

22

Attach engine removal fixture

Mobile workshop crane
gotis://H_00.12_03.0
Engine removal fixture for cars and vans
gotis://A_01_08.1

AR01.10-D-2400-09SD

23

Unscrew screw/bolt (18)



*BA22.10-N-1004-01S

24

Unscrew bolt (19) and place ground (20) to one side



*BA22.10-N-1004-01S

25

Carefully raise engine (21) with transmission (11) and drive out towards the front

 Aid of helper required
Mobile workshop crane
gotis://H_00.12_03.0
Engine removal fixture for cars and vans
gotis://A_01_08.1

 Installation: When replacing engine (21), modify detachable parts.

Ensure correct seating of engine mounts (arrows).

26

Install in the reverse order

27

Bleed clutch operating system

AR25.20-D-0070SD

28

Check that shift mechanism functions correctly

 The transmission (11) must shift smoothly, adjust the shift cables if necessary.

See: 

Adjust transmission shift cables (11)

AR26.60-D-6633A

29

Attach STAR DIAGNOSIS, read out fault memory, delete if necessary and perform initialization in menu item Control unit adaptation

 Only if flywheel or clutch plate has been replaced..



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-D-2000-04SD

 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.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

30

Conduct engine test run and check engine for leaks

Number

Designation

Engine
646

BA14.40-N-1001-02D

Pipe clamp connecting catalytic converter to turbocharger

Nm

15

BA14.40-N-1006-02D

Nut connecting bracket to catalytic converter

Nm

23

BA14.40-N-1007-02D

Bolt, bracket to transmission

Nm

23

Number

Designation

Engine
646
in model
906

BA20.40-N-1002-01N

Viscous clutch on coolant pump

Nm

45

Number

Designation

Engine 646.9

BA22.10-N-1004-01S

Bolt, engine mount to front engine support

Nm

58

Number

Designation

Model
906 without code ZG1/ZG2/ZG3/
ZG4

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

15

Stage 2

°

90

Screw headE14

Stage 1

Nm

15

Stage 2

°

70

M121.5

Screw headE14

Stage 1

Nm

15

Stage 2

°

50

Screw headE18

Stage 1

Nm

60

Stage 2

°

60

Number

Designation

Model
906 with code ZL3

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

-

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

15

Stage 2

°

50

Screw headE18

Stage 1

Nm

60

Stage 2

°

60

Number

Designation

Model
906
with engine 646

BA46.30-N-1001-01M

High pressure expansion hose to power steering pump

Nm

38

Number

Designation

Model
906 with code HH9

BA83.30-N-1010-01F

Screw/bolt, refrigerant line to refrigerant compressor

Nm

22

Number

Designation

Order number

BR00.45-Z-1001-06A

Long-life grease

A 000 989 63 51 11