Remove/install engine

AR01.10-T-2400A

Remove/install engine

14.2.12

25.1.07

ATF automatic transmission fluid

Transmission 721.407/804

*BF27.00-N-1001-01E

 

Remove/install

 Danger!

Risk of injury to skin and eyes caused by handling hot or glowing objects.

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

AS00.00-Z-0002-01A

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by 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.

AS20.00-Z-0001-01A

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

 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.

AS54.10-Z-0001-01A

1

Disconnect electrical line on the battery



Notes on battery

All models

AH54.10-P-0001-01A

2

Open engine compartment flap

3

Remove additional flap together with cross strut

AR88.60-T-7000A

4

Open left rear maintenance flap

5

Detach engine compartment paneling under the transmission

6

Remove seat row above the transmission maintenance flap

AR91.21-T-4460A

7

Open maintenance flap above the transmission in the vehicle interior

8

Open maintenance flap above the engine in the vehicle interior

9

Remove tailpipe of exhaust system

AR49.10-T-7150A

10

Take off cross strut of engine compartment flap

 If necessary for better accessibility.

AR88.40-T-1100-01A

11

Drain coolant



Drain/fill in coolant

AP20.00-T-2080-01A



Notes on coolant

All engines

AH20.00-N-2080-01A



*BF20.00-N-1001-01D

12

Remove coolant pipe (17)

AR20.20-T-7450A

13

Remove fuel lines on injection pump

AR07.11-T-8410-01A

14

Disconnect all electrical connectors to the engine

 Identify the installation position of the electrical connectors in order to rule out mixing up.

 Installation: Note marking.

15

Take off fixture of engine wiring harness at engine

 The engine wiring harness remains with the bracket on the vehicle frame.

16

Disconnect electrical connectors from the solenoid valve and glow plug on the flame starting system

 It is not necessary to remove the complete flame starting system.

AR15.45-T-1000A

17

Detach fuel line on solenoid valve of flame starting system

 If necessary collect fuel which runs out in a suitable container.

AR15.45-T-1000A

18

Detach bracket of cable set for oil temperature sensor and oil pressure sensor

 The cable set remains with the bracket on the vehicle frame.

19

Remove charge air pipe

AR09.41-T-1311A

20

Remove air intake pipe

AR09.10-T-8131A

21

Detach exhaust flex pipe from turbocharger

AR49.10-T-7160A

22

Detach longitudinal strut of engine compartment paneling

AR61.20-T-1000-01A

23

Remove oil filler neck together with oil separator

AR01.20-T-9540A

24

Detach hydraulic oil lines on the power steering pump

 Collect hydraulic fluid which runs out in a suitable container.



*BA46.30-N-1002-01H



*BA46.30-N-1003-01H



*001589672100

25

Disconnect wiring harness from alternator

AR15.40-T-5032-01A

26

Disconnect wiring harness from starter

 Only carry out the operation steps which are required for disconnecting the wiring harness.

AR15.30-T-7100A

27

Detach coolant lines (13) from the associated coolant hoses

28

Detach lower coolant hose (16) with coolant pipe (17) from the coolant pump (18)

29

Remove upper coolant pipe on heat exchanger from transmission

Only with transmission 721.407/803/804/805/
913/914/915/916/917

AR20.20-T-7450-03A

30

Support engine and transmission underneath and secure to prevent them from falling down

Major assembly lifting platform / scissors pallet forklift gotis://A_01_07.1

31

Remove front engine mounts

AR22.10-T-4330A

32

Attach cranking device for starter ring gear to inspection hole of timing case

Only with transmission 721.407/803/804/805/
913/914/915/916/917

 Installation:The cranking device must be removed before starting the engine.



*407589006300

33

Remove screw/bolts (15) from the torque converter at the drive plate

Only with transmission 721.407/803/804/805/
913/914/915/916/917

 By turning the engine with the aid of the turning device the screw/bolts (15) become accessible in sequence and can be unscrewed.

 With transmission 721.407/804/913/914/915/916/917

*BA27.10-N-1007-04F



*001589672100

34

Remove screw/bolts (14) of transmission on timing case

All transmissions

 With automatic transmission 721.407/804/913/914/915/916/917

*BA27.10-N-1006-04F

 With manual transmission 714.669/675/692

*BA25.10-N-1004-01F



*001589672100

35

Remove rear engine mount

AR22.10-T-1160A

36

Remove engine

 Use the major assemblies lifter to lower the engine carefully and move out to the rear.

Major assembly lifting platform / scissors pallet forklift gotis://A_01_07.1

37

Install in the reverse order



Checking

38

Check engine oil level, correct if necessary



Engine oil and filter change

AP18.00-T-0101A



*BF18.00-N-1001-01D

39

Check transmission oil level, correct if necessary

All transmissions



Manual transmission - check, correct oil level

With transmission 714.669/692

AP26.00-T-2610A



Automatic transmission - check, correct oil level

With transmission 721.407/804/913/914/
915/916/917

AP27.00-T-2710A



Notes on operating fluids

Transmission 721.103/104/108/109/141/151/172/
181/182/913/914/915/916/917

AH00.40-N-0001-01A

 Transmissions 714.669/692

*BF26.00-N-1001-01D

 Transmission 721.407/804/913/914/
915/916/917

*BF27.00-N-1001-01E

40

Check power steering oil level and correct if necessary



Power steering - checking and correcting oil level

AP46.00-T-4611A



*BF46.20-N-1001-01B

41

Conduct a road test

 Check function and leaktightness of major assemblies and their connections.

Number

Designation

Engines 447, 489

BA25.10-N-1004-01F

screw/bolt connecting clutch housing to timing case

Nm

45

Number

Designation

Trans-mission 721.407/
804

Transmission 721.913/914/
915/916/917

BA27.10-N-1006-04F

Screw/bolt, automatic transmission to timing case

Nm

44

44

BA27.10-N-1007-04F

Screw/bolt, torque converter to drive plate

Nm

69

69

Number

Designation

Steering 765.866

BA46.30-N-1002-01H

Pressure line to power steering pump

Nm

60

BA46.30-N-1003-01H

Suction line to power steering pump

Nm

90

Number

Designation

Engines 447, 489

BF18.00-N-1001-01D

Engine oil

Filling capacity with oil filter

Liters

20.5 to 24.5

Filling capacity with oil filter and heat exchanger

Liters

-

Automatic engine oil replenishment reservoir

Liters

16

Specifications for Operating Fluids

Sheet

BB00.40-P-0228-01A

Sheet

BB00.40-P-0228-03A

Sheet

BB00.40-P-0228-05A

Number

Designation

Engine 447

Engine 489

BF20.00-N-1001-01D

Filling capacity for coolant

without VOITH retarder

Liters

76 to 92

70 to 80

with VOITH retarder

Liters

-

-

Specifications for Operating Fluids

Sheet

BB00.40-P-0310-01A

BB00.40-P-0310-01A

Sheet

BB00.40-P-0325-02A

BB00.40-P-0325-02A

Number

Designation

Transmission
714.669

Transmissions
714.690/692

BF26.00-N-1001-01D

Gear oil

Filling capacity

Liters

15

12.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-01A

BB00.40-P-0235-01A

-

Sheet

-

-

-

Sheet

-

-

-

Sheet

-

-

-

Sheet

-

-

-

Sheet

-

-

Number

Designation

Transmission 721.407/804

Transmission 721.913/914/915/916/917

BF27.00-N-1001-01E

ATF automatic transmission fluid

Filling capacity, first filling

Liters

25 to 28

30

Filling capacity, oil change

Liters

21 - 23

14 to 16

Specifications for Operating Fluids

Sheet

BB00.40-P-0236-01A

AH00.40-N-0001-01A

Sheet

BB00.40-P-0236-08A

-

Sheet

BB00.40-P-0236-81A

-

Number

Designation

Steering 765.866

BF46.20-N-1001-01B

Steering gear oil

Liters

7.5 to 8.5

Specifications for Operating Fluids

Sheet

BB00.40-P-0235-01A

Sheet

-

Sheet

-

Sheet

-