Remove/install engine

AR01.10-D-2400NB

Remove/install engine

14.2.12

 

Remove/install

 Danger!

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

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

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

AH00.00-N-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 engine wiring harness on vehicle side

AR15.18-D-1000-02NB



Notes on battery

AH54.10-P-0001-01A

2

Remove radiator unit

AR20.20-D-3871NA

3

Remove engine hood

AR88.40-D-3000NA

4

Remove dust filter

Replace dust filter for heating/air conditioning

 Only for vehicles with code (H06) A/C, code (HH9) Regulated air conditioning, (Tempmatic), code (H81) Ventilation system with filter.

AP83.00-D-8381A

5

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

 Installation: Replace seal (7).



*BA46.30-N-1003-01A

6

Detach fuel hoses (10, 11) at fuel filter

 Installation: Inspect hose clamps and fuel hoses (10, 11) and replace if necessary.

7

Detach refrigerant line (13) at refrigerant compressor

 Installation: Install new sealing ring (14). Only for code (H08) Heavy duty air conditioning



*BA83.30-N-1009-02A



Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

8

Disconnect vacuum line (8) for brake booster from vacuum pump

 Press detents on quick-release fitting of vacuum line (8) together and detach.

9

Detach coolant hose (4) from exhaust gas recirculation positioner (3).

10

Unplug electrical connector at exhaust gas recirculation positioner (3)

11

Detach charge air hose (12) at charge air manifold

 Pull spring at charge air manifold toward top.

 Installation: Replace sealing ring at charge air hose (12).

12

Disconnect electrical connectors from boost pressure sensor and boost pressure temperature sensor at charge air pipe and remove charge air pipe

13

Detach coolant hose (1) at right side of coolant pipe at the cylinder head

 Installation: Check condition of hose clamps and coolant hose (1); replace if necessary.

14

Remove air intake hose (9)

15

Detach exhaust pipe (2) at bracket

16

Detach exhaust pipe (2) at turbocharger and place to the side

 Installation: Check clamps, install new ones if necessary.

17

Detach propshaft (18) at output flange

 Installation: Replace bolts (17).



*BA41.10-N-1001-01B

18

Detach refrigerant line at oil pan

 Only for code (H08) Heavy duty air conditioning

 Do not detach refrigerant line at refrigerant compressor

19

Remove refrigerant compressor

Only for code (H08) Heavy duty air conditioning

AR83.55-D-5300NC

 Secure refrigerant compressor with refrigerant lines connected and electrical line connected to one side.

20

Release electrical connector (19) at automatic transmission and disconnect (arrows), expose wiring harness of automatic transmission (20)

 Installation: Install new cable ties.

21

Press safety catches at selector lever cable (24) together and take selector lever cable (24) out of the bracket (23)

 Installation: The safety catches must latch in securely at the selector lever cable (24).

22

Pry off ball socket (25) from gearshift lever (26)

 Installation: Grease ball socket (25) with multipurpose grease.

*BR00.45-Z-1008-06A

23

Support the automatic transmission

 Insert a suitable wooden chock between automatic transmission and front axle crossmember.

24

Unscrew nuts (22) and remove the rear engine crossmember (21) complete

 Counterhold the bolts at the transmission bearing bracket.

Lower automatic transmission slowly onto the wooden wedge



*BA22.10-N-1004-01L

25

Detach front cross plate

 Pay attention to separating cut (A) on left and right.

26

Deburr, prime and paint separating cuts (A) on the body side

27

Adjust engine removal device (30)

 Position engine removal device (30) into the final rear detent (arrow) and secure with a locking bolt.

28

Attach engine removal device (30) into the front lifting eyes and at the rear of the cylinder head

29

Unscrew bolts (28) at left and right engine mount (29)

 The ground line and the bracket for a hydraulic line are also attached to the engine mount (29) on the left.

 Installation: When lowering the engine, position the engine support onto the engine mount (29), screw in the bolts (28) on the left and right and tighten by hand.

Then lower engine fully and tighten bolts (28) on left and right.



*BA22.10-N-1002-01L

30

Lift out engine together with transmission

 When lifting out, ensure that electrical and hydraulic lines are not damaged.

31

Install in the reverse order

32

Bleed fuel system

 Switch on ignition three times for approx. 6 seconds without starting the engine.

 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

 Danger!

Risk of explosion from 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

33

Allow the engine to run until warm, switch the engine off and check the fuel system for oil leaks and leaktightness.

34

Encode radio, set clock

Number

Designation

Engine 647.981

BA22.10-N-1002-01L

Bolt, engine bracket to front engine mount

Nm

83

BA22.10-N-1004-01L

Nut/bolt, rear engine crossmember to console

Nm

45

Number

Designation

Model
690.6, 901, 902, 903, 904, 905 except Minibus Sprinter Low Floor

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Screw headE18

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

Model
WD1/WD2/ WD3/
WD6/ WD7/
XD1/ XD2/XD3/
XD4/XD5/ XD6/
XD7/
YD1/YD2/ YD3/
YD4/ YD5/YD6/
YD7

BA41.10-N-1001-01B

Propeller shaft on transmission

M101

Stage 1

Nm

70

Stage 2

°

-

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

M121.5

Screw headE14

Stage 1

Nm

-

Stage 2

°

-

Screw headE18

Stage 1

Nm

-

Stage 2

°

-

Number

Designation

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

Model
WD1/WD2/
WD3/WD6/
WD7/XD1/
XD2/XD3/
XD4/XD5/
XD6/XD7/
YD1/YD2/
YD3/YD4/
YD5/YD6/
YD7

BA46.30-N-1003-01A

High pressure expansion hose to power steering pump

–

Nm

–

–

VDA pump

Nm

38

38

VT pump

Nm

-

-

Number

Designation

Model
901.6, 902.6, 903.6, 904.6, WD2, WD3,
WD6, WD7 with code HH7/H08

Model
901.6, 902.6, 903.6, 904.6,
905.6
with code HH9

Model
WD1/WD2/
WD3/WD6/
WD7/XD1/
XD2/XD3/
XD4/XD5/
XD6/XD7/
YD1/YD2/
YD3/YD4/
YD5/YD6/
YD7
with code HH9

BA83.30-N-1009-02A

Bolt for refrigerant line on refrigerant compressor

Nm

21 (2)

21 (2)

21 (2)

Number

Designation

Order number

BR00.45-Z-1008-06A

Silicone-based grease

A 001 989 28 51 10