Remove/install engine

AR01.10-D-2400NA

Remove/install engine

08.10.2019

Engine

612.981 in model 903.61/62/66/67, 904.61/62/66

with code ZU9 (National version for Mexico)

Engine

612.981 in model 903.61/66/67, 904.61/66

with code ZU7 (National version for Canada)

Engine

612.981 in model 903.61/66/67, 904.61/66

with code ZU8 (National version for USA)

1

Heater feed coolant hose

2

Front exhaust part

3

Bracket

4

Heater return coolant hose

5

Return flow pipe

6

High pressure pipe

7

Sealing ring

8

Vacuum line

9

Air intake hose

10

Fuel line

11

Fuel line

12

Vacuum line

13

Cylinder head cover trim panel

14

Charge air hose

15

Refrigerant line

16

Sealing ring

17

Screw

18

Propeller shaft

19

Connector

20

Electrical line

21

Rear engine support

22

Nuts

23

Bracket

24

Selector lever cable

25

Linkage rod

26

Ball socket

27

Locking clamp

A

Cut edges

28

Screw

29

Engine mount

30

Engine removal device

 

Remove/install

 Danger

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer.

AS00.00-Z-0010-01A

Topical note

Notes on self-locking nuts and bolts

AH00.00-N-0001-01A

1

Drain air conditioning system

Drain, evacuate and recharge air conditioning, check for proper operation and check for leaks

AR83.30-D-1760A

 Only for vehicles with code (HH6) air conditioning, roof equipment, code (HH7) additional air conditioning in the rear passenger compartment, code (HH9) regulated air conditioning, (Tempmatic), code (HK2) air conditioning in the rear passenger compartment with underfloor condenser.

2

Remove engine hood

Remove/install engine hood

AR88.40-D-3000NA

 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 orifices. Risk of death due to voltage U >= 25 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.

AS54.10-Z-0001-01A

3

Disconnect engine wiring harness on vehicle side

Disconnect, connect engine wiring harness at vehicle side

AR15.18-D-1000-02NA

Topical note

Notes on battery

AH54.10-P-0001-01A

 Do not disconnect engine wiring harness from starter.

4

Remove dust filter



Replace dust filter for heating/air conditioning

AP83.00-D-8381A

 Only for vehicles with code (H06) air conditioning, code (HH9) regulated air conditioning, (Tempmatic), code (H81) ventilation system with filter.

5

Drain off coolant

Drain/pour in coolant

AR20.00-D-1142NA

 On the cooler.

6

Remove cover of the cylinder head cover (13)

Remove/install cylinder head cover trim panel

AR01.20-D-5015NA

 Accessibility of the lifting lugs is improved.

7

Remove charge air hose (14) from the mixer housing with the exhaust gas recirculation

 Pull spring (arrow) upward.

 Installation: Check sealing ring of the charge air hose (14) and replace if necessary.

8

Remove complete cooler unit

Remove/install radiator

AR20.20-D-3865NA

 Do not disassemble cooler unit.

9

Remove high-pressure line (6) and return line (5) from the power-steering pump

 Installation: Replace sealing ring (7).

 High pressure expansion hose to power steering pump

*BA46.30-N-1003-01A

10

Remove fuel lines (10, 11) from the fuel filter

 Installation: Replace collar clamps.

11

Remove refrigerant line (15) from A/C compressor

 Installation: Install new sealing ring (16).

 Screw/bolt, refrigerant line on refrigerant compressor

BA83.30-N-1009-02A

12

Remove vacuum line (8) for brake booster from the vacuum pump

 Press together notches on the quick-release fastener and detach vacuum line (8).

13

Remove heater return coolant hose (4) from the heater circulation pump

14

Remove heater feed coolant hose (1) from the side coolant pipe on the cylinder head

15

Remove air intake hose (9) from the air filter housing

16

Remove vacuum line (12) from the exhaust gas turbocharger vacuum cell

17

Remove nuts from the bracket (3) for the front exhaust part (2)

18

Remove front exhaust part (2) from the exhaust gas turbocharger

19

Remove propeller shaft (18) from the output flange

 Installation: Replace screws (17).

 Propeller shaft to transmission

*BA41.10-N-1001-01B

20

Release plug (19) from the automatic transmission and detach (arrows); expose electric line (20)

 Replace cable tie.

21

Release locking clamp (27)

22

Press together safety catches on the selector level cable (24) and remove selector level cable (24) from the bracket (23)

 Installation: The selector level cable (24) must engage securely.

23

Remove linkage (25) from the guide in the ball socket (26)

 Installation: Mount linkage (25) in selector lever position "N." The linkage (25) adjusts itself automatically.

24

Support automatic transmission from below using a suitable device

25

Remove nuts (22), slowly lower rear engine carrier (21), and remove completely

 The automatic transmission is on the front axle crossmember.

 Nut/bolt, rear engine crossmember to mounting console

*BA22.10-N-1004-01L

26

Saw off front bulkhead panel from the cut edges (A)

 Deburr cut edges (A) and coat with anti-corrosion agent.

27

Adjust engine removal device (30)

 Lock screw in the 10th notch (arrow) of the engine removal device (30).

28

Hook engine removal device (30) into the front and rear lifting lugs (arrows) on the cylinder head

29

Remove screws (28) from the left and right engine mount (29)

 Installation: When lowering, position the engine carefully the left and right engine mounts (29), screw in the screws (28), and tighten finger-tight up to end stop. Then, lower the engine completely and tighten screws (28). Observe bracket and ground line on the left engine mount (29).

 Bolt, engine support to front engine mount

*BA22.10-N-1002-01L

30

Carefully lift out engine with transmission

 Observe cable duct for alternator wiring harness and exhaust bracket.

31

Install in the reverse order

32

Check cooling system for leaktightness

Inspect cooling system for leaks

AR20.00-D-1010C

33

Evacuate air conditioning system, refill it, and then check the system to make sure that it functions correctly and does not leak

Drain, evacuate and recharge air conditioning, check for proper operation and check for leaks

AR83.30-D-1760A

 Only for vehicles with code (HH6) air conditioning, roof equipment, code (HH7) additional air conditioning in the rear passenger compartment, code (HH9) regulated air conditioning, (Tempmatic), code (HK2) air conditioning in the rear passenger compartment with underfloor condenser.

34

Bleed low pressure fuel circuit

Bleed low pressure fuel circuit

AR07.16-D-0100A

 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.

AS00.00-Z-0005-01A

 Danger

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.
Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

35

Check oil thickness of the vehicle and leak tightness of the fuel system

 Allow engine to run, switch off, and check for leak tightness.

36

Code radio; set time

 Engine mounts, engine supports

Number

Designation

Engine 612.981

BA22.10-N-1002-01L

Bolt, engine support to front engine mount

Nm

83

 Engine mounts, engine supports

Number

Designation

Engine 612.981

BA22.10-N-1004-01L

Nut/bolt, rear engine crossmember to mounting console

Nm

45

 Propeller shaft

Number

Designation

Model 690.6, 901, 902, 905 (except 905.613)
Model 903.0/4/6, 904.0/4, 904.6 (except 904.663)
except code ZG1 (Engageable all-wheel drive)
except code ZG2 (Permanent all-wheel drive)
except code ZG3 (Engageable all-wheel drive with gear reduction)
Model 905.613
Except Sprinter low floor minibus

Model 904.663
Model 905.613
Sprinter low-floor minibus

BA41.10-N-1001-01B

Propeller shaft to transmission

M101

Stage 1

Nm

70

70

Stage 2

°

-

-

M121.5

Hexalobular bolt

Stage 1

Nm

-

-

Stage 2

°

-

-

Torx bolt E14

Stage 1

Nm

-

-

Stage 2

°

-

-

 Power steering pump

Number

Designation

Model 690.6, 901.6, 902.6, 903.6, 904.6, 905.6, 909

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

–

VDA pump

Nm

38

VT pump

Nm

–