G01.10-3102-09
1 Power steering pump
2 Air hose
3 Vacuum line connection
4 Engine support
5 Vacuum line (boost pressure)
6 Turbocharger
7 Vacuum line (exhaust gas recirculation)
| Remove/install | ||
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 ground cable from battery | ||
3 | Remove front engine compartment flap | ||
4 | Pull out intake hose (air filter to engine) | ||
5 | Remove shift lever | ||
6 | Raise cab | ||
Danger! | Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from 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. | |
7 | Drain coolant | ||
| Notes on coolant | All engines | |
8 | Unscrew drive shaft at transmission and remove | | |
9 | Unbolt front exhaust pipe at turbocharger (6) | Use new nuts. | |
10 | Remove fan belt | ||
11 | Remove air hose (2) (turbocharger to charge air cooler) | ||
12 | Remove air hose (charge air cooler to engine) | ||
13 | Remove air hose (charge air distribution pipe) | ||
14 | Unscrew compressor line at line bracket | ||
15 | Remove clutch cylinder | ||
16 | Unscrew line bracket for engine wiring harness at the engine | ||
17 | Disconnect engine wiring harness | ||
18 | Detach water hoses (radiator to engine) | ||
19 | Detach coolant hose at bottom right of radiator | ||
20 | Unclip ball head support | Ball head sits at the front left. | |
21 | Pull out vacuum line from connection (3) at the vacuum pump | ||
22 | Pull out vacuum lines (5, 7) at the vacuum pumps for the exhaust gas recirculation and boost pressure | The vacuum pumps sit to the right of the radiator. | |
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. | |
23 | Pull out fuel lines for feed and return at the separation point | Set of plugs Seal fuel lines with plugs. | |
24 | Unscrew suction and pressure line (1, ) at the power steering pump | ||
25 | Unscrew transmission at frame side | Transmission is removed with engine, see instructions: Remove transmission | |
26 | Unscrew engine support (4) at front left and right | ||
27 | Remove engine with transmission | Engine hoist (self-locking) | |
28 | Install in the reverse order | ||
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 engine | Secure vehicle to prevent it from moving. | |
29 | Run engine and inspect for leaks | ||
30 | Inspect cooling system for leaks | ||
31 | Read out fault memory and erase | Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Engine Diagnosis Manual: Register 0: Connecting and Using Test equipment. |
Turbocharger
Number | Designation | Engine 602.981 | |
BA09.40-N-1001-01L | Bolt connecting flange connection for turbocharger/front exhaust pipe | Nm | 25 |
Propeller shaft
Number | Designation | Model 408.216 | |
BA41.10-N-1004-01A | Bolt connecting driveshaft to transmission | Nm | 62 |
Set of stop plugs
129 589 00 91 00
Workshop equipment
WE58.40-Z-1012-11A | Load regulator (engine hoist), self-locking |
Referenced documents
- ah2000n208001a Notes on coolant
- ar2610g0020b Remove/install transmission
- ar6080g0010a Tilt cab to repair position, tilt back
- 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.
- as2000z000101a Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.
- 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