Engine assembly removal and installation procedure |
251 | Auxiliary air tank |
252 | Input electrical connector (16 pin) |
253 | Fuel inlet pipe |
254 | Fuel outlet pipe |
255 | Make up line hose |
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49 | Coolant hose |
256 | De-aeration tank hose |
257 | Starter motor wiring harness bunch tag |
258 | Power steering pump inlet hose |
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230 | Adaptor |
259 | Power steering pump outlet hose |
260 | Air compressor outlet pipe |
261 | Air compressor outlet pipe mounting bracket |
262 | Air compressor inlet pipe (worm-drive clamp) |
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263 | Turbocharger air inlet hose |
264 | Electrical connections of starter motor (red and black cable) |
265 | Ground connection (brown cable) |
266 | Pneumatic hose |
Y01.10-0117-06
267 | Gear shifting cable mounting bracket |
268 | Gear shift lever mounting bracket |
269 | Charge air cooler (CAC) inlet pipe flexible hose |
270 | Charge air cooler (CAC) outlet pipe flexible hose |
271 | Electrical connection (black cable) of alternator |
Y01.10-0118-06
272 | Alternator connector |
273 | Alternator ground connection |
274 | Turbocharger hose |
275 | Chassis wiring harness cable tie |
276 | Battery cable |
Y01.10-0119-06
277 | Chain sling |
278 | Engine lifting eye |
279 | Engine mounting bolts |
280 | Engine bed mounting bracket |
281 | Engine bed mounting bracket rubber boot |
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282 | Bed rubber boot top and bottom |
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Warning | 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. | Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. | |
Topical note | Notes on self-locking nuts and bolts | ||
| Remove/install | ||
1 | Switch off ignition. | Secure the vehicle to prevent it from rolling. | |
Warning | Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. 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. | |
2 | Drain coolant from radiator. | ||
Topical note | Notes on coolant | ||
3 | Remove transmission from the vehicle. | ||
4 | Depressurize auxiliary air tank (251). | ||
5 | Disconnect the input electrical connector (16 pin) (252) from the MR control unit. | ||
Danger | 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. | No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only. | |
6 | Remove fuel inlet (253) and outlet pipe (254) from the fuel filter and fuel pump. | Fuel inlet and outlet pipe to fuel filter and fuel pump | |
7 | Remove make up line hose (255) by loosening the worm-drive clamp at water pump end. | ||
8 | Remove de-aeration tank hose (256) by loosening the worm-drive clamp at water pump connecting piece end. | ||
9 | Remove coolant hose (49) by loosening the worm-drive clamp at water pump outlet pipe end. | ||
10 | Remove fan. | ||
11 | Remove battery to starter motor wiring harness bunch tag (257) from right side of the engine. | ||
Warning | Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid. | Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. | |
12 | Remove power steering pump inlet hose (258) by removing the hose adaptor at power steering pump end and collect the draining oil in a suitable container. | ||
13 | Remove power steering pump outlet hose (259) by removing the hose adaptor at the pump end. | Move both the pipe and hold it in upward direction with the help of cable tie, so that oil not fall down. | |
Power steering pump outlet hose adapter to pump | |||
14 | Remove air compressor outlet pipe (260) by removing the adaptor (230) at air compressor. | Air compressor outlet pipe adapter | |
15 | Remove air compressor outlet pipe mounting bracket (261) from engine and near engine bed mounting area. | Air compressor outlet pipe mounting bracket to the engine | |
16 | Loosen worm-drive clamp of the air compressor inlet pipe (262) and remove the hose from the turbocharger air inlet pipe. | ||
17 | Remove turbocharger air inlet hose (263) by loosening the worm drive clamp. | ||
18 | Remove electrical connections of starter motor (red and black cable) (264). | Starter motor electrical connectors to starter motor | |
19 | Remove the ground connection (brown cable) (265) from flywheel housing. | Ground connection to the flywheel housing | |
20 | Remove pneumatic hose (266) connector lock nut from the exhaust brake cylinder. | Pneumatic hose connection lock to exhaust brake cylinder | |
21 | Remove the gear shifting cable mounting bracket (267) from turbocharger. | ||
22 | Remove gear shift lever mounting bracket (268) from driver seat mounting bracket. | Gear shift lever mounting bracket to driver seat mounting bracket | |
23 | Remove exhaust pipe with muffler. | ||
24 | Remove the worm-drive clamps of the charge air cooler (CAC) inlet pipe flexible hose (269) and charge air cooler (CAC) outlet pipe flexible hose (270). | CAC outlet and inlet pipes to the engine | |
25 | Remove electrical connection of (black cable) alternator (271). | Alternator electrical connection nut to the alternator | |
26 | Disconnect alternator connector (272) from alternator. | ||
27 | Remove the alternator ground connection (273) from alternator. | Alternator ground connection to alternator | |
28 | Remove turbocharger hose (274) in CCV (closed crankcase ventilation). | Loosen worm drive clamps of breather pipe from breather hose bracket. | |
Worm drive clamps of breather pipe to breather hose bracket | |||
29 | Remove chassis wiring harness cable tie (275) from flywheel housing. | ||
Danger | 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 poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC. | No fires, sparks, open flames, or smoking. Wear acid-resistant gloves, clothing, and glasses. Pour battery acid only into suitable and appropriately marked containers. | |
30 | Remove the battery cable (276) from flywheel. | ||
Topical note | Notes on battery | ||
Battery cable to the flywheel housing | |||
31 | Insert the chain sling (277) to the engine lifting eye (278). | | |
32 | Remove engine mounting bolts (279) from both left hand side and right hand side of the vehicle. | Engine mounting bracket bolts at both LHS and RHS | |
33 | Lift engine with flywheel housing from the vehicle. | | |
Place it gently over a stand. | |||
34 | Remove the engine bed mounting bracket (280) from chassis. | Engine bed mounting bracket to chassis | |
35 | Remove the engine bed mounting bracket rubber boot (281). | Install engine bed mounting bracket rubber boot | |
36 | Remove the bed rubber boot top and bottom (282) from bed mounting bracket. | ||
37 | Install in the reverse order. | ||
38 | Fill power steering fluid in the reservoir and refill coolant. | Power steering oil (ZF-8046) | |
Mixture ratio for coolant |
Referenced documents
- ah0000n000101a Notes on self-locking nuts and bolts
- ah2000n208001a Notes on coolant
- ah5410p000101a Notes on battery
- ah5410p000101a
- ar0110y2403a Detaching detachable engine components
- ar0110y2404a Installing detachable engine parts
- ar2000y1142a Drain/pour in coolant
- ar2610y0020a Remove/install transmission
- ar4910y7140a Remove/install the exhaust system
- 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.
- as0000z001301a Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid.
- 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