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 | Vacuum line |
14 | Charge air hose |
15 | Refrigerant line |
16 | Sealing ring |
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17 | Nut |
18 | Tachograph sensor |
19 | Sealing ring |
20 | Backup light switch plug and engine start/stop switch |
21 | Rear engine support |
22 | Nut |
23 | Nut |
24 | Shift cable |
25 | Shift cable |
26 | Ground cable |
27 | Clutch line |
28 | Fuse |
29 | Sealing ring |
30 | Propeller shaft |
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31 | Screw |
32 | Engine mount |
33 | Engine removal device |
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| Remove/install | ||
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. | |
1 | Drain air conditioning system | ||
Engine 612.981 in model 902.6, 903.6, 904.6, 905.6 | |||
2 | Remove engine hood | ||
3 | Disconnect engine wiring harness on vehicle side | ||
Do not disconnect engine wiring harness from starter. | |||
4 | Remove dust filter | ||
| |||
5 | Drain off coolant | ||
On the cooler | |||
6 | Remove charge air hose (14) from the mixer housing with the exhaust gas recirculation | Pull spring (arrow) upward | |
Installation: Check sealing ring; replace if necessary | |||
7 | Remove complete cooler unit | ||
8 | Remove high-pressure line (6) and return line (5) from the power-steering pump | Installation: Install new sealing ring (7) | |
High pressure expansion hose to power steering pump | |||
9 | Detach vacuum line (13) from the charge air manifold vacuum cell | ||
10 | Remove fuel lines (10, 11) from the fuel filter | Installation: Install new clamps | |
11 | Remove refrigerant line (15) from A/C compressor | Engine 612.981 in model 902.6, 903.6, 904.6, 905.6 | |
Installation: Install new sealing ring (16). | |||
12 | Remove vacuum line (8) for brake booster from the vacuum pump | Quick-release fastener (press together notches and detach). | |
13 | Remove heater return coolant hose (4) from the adapter | ||
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 (30) from the output flange | Propeller shaft to transmission | |
20 | Remove tachograph sensor (18) from the transmission | Installation: Install new sealing ring (19). | |
21 | Disconnect plug (20) from the backup light switch and engine start/stop switch | ||
22 | Unhook shift cables (24, 25); to do this, press the shackles, unhook from the bracket, and unclip shift cables from the ball heads | Only for manual transmission G20, G32 | |
Caution | Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid | Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. | |
23 | Remove bracket of the clutch line (27) from the transmission, remove retainer (28), and pull clutch line (27) out of the clutch slave cylinder in the transmission | ||
Topical note | Brake fluid notes | ||
Only for manual transmission G20, G32 | |||
24 | Remove ground line (26) from the frame | ||
25 | Remove nut (22) bearing from transmission | Bolt, rear engine mount to transmission | |
26 | Remove nuts (23), slowly lower rear engine carrier (21), and remove completely | Transmission is on the front axle crossmember. | |
27 | Remove trim panel of cylinder head cover | ||
Accessibility of the lifting lugs is improved. | |||
28 | Adjust engine removal device (33) | Lock screw in the 9th notch (arrow) of the engine removal device (33). | |
29 | Hook engine removal device (33) into the front and rear lifting lugs (arrows) on the cylinder head | ||
30 | Remove screws (31) of the engine carrier from the engine mount on both sides | Bolt, engine support to front engine mount | |
31 | Carefully lift out engine with transmission | Observe cable duct for the alternator wiring harness, exhaust bracket, and front bulkhead panel | |
32 | Install in the reverse order | ||
33 | Bleed clutch operating system | ||
34 | Check cooling system for leaktightness | ||
35 | Charge air conditioning system | Engine 612.981 in model 902.6, 903.6, 904.6, 905.6 | |
36 | Bleed low pressure fuel circuit | ||
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. | |
37 | Check oil thickness | Allow engine to warm up, switch off, and check leak tightness | |
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. | |
38 | Inspect fuel system for leaks | Allow engine to run, switch off, and check for leak tightness. | |
39 | Code radio; set time |
Propeller shaft |
Number | Designation | Model 690.6, 901, 902, 905 (except 905.613) | Model 903.6, 904.6 (except 904.663) | ||||
BA41.10-N-1001-01B | Propeller shaft to transmission | M101 | Stage 1 | Nm | 70 | - | |
Stage 2 | ° | - | - | ||||
M121.5 | Hexalobular bolt | Stage 1 | Nm | - | - | ||
Stage 2 | ° | - | - | ||||
Torx bolt E14 | Stage 1 | Nm | - | - | |||
Stage 2 | ° | - | - |