Remove/install engine with transmission

AR01.10-T-2401AA

Remove/install engine with transmission

21.10.11

 

Remove/install

 Danger!

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities

No parts of the body or limbs should be within the operating range of the mechanism when moving components.

AS00.00-Z-0009-01A

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.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A



Before installing, clean all sealing surfaces. New sealing rings must be installed at banjo bolts and quick-connectors. After detaching fuel lines, seal with a plug.

1

Disconnecting the battery

AR54.18-T-0002AA

2

Take off service flap at rear left exhaust

3

Detach flap of left rear engine mount

4

Open service flap at left rear of engine

5

Open liftgate

6

Remove rear bumper

AR88.20-T-2200AA

7

Open service flap at rear right of expansion reservoir

8

Remove passenger seats above service flaps of transmission and engine compartment

AR91.21-T-4460D

9

Remove engine service flap

AR88.40-T-1100-03AA

10

Remove transmission service flap

11

Raise vehicle

AR00.60-T-1000AA

12

Detach lower engine compartment paneling

AR61.20-T-1105AA

 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

13

Drain coolant

 Shutoff cocks of heating must be closed.

 Filling: Temperature regulators must be turned to "Heating".

14

Remove exhaust system

AR49.10-T-7140AA

15

Remove shift cables for gearshift from bracket and relay lever

 Do not alter settings of the shift cables.

16

Detach clutch booster (8) from transmission

 Disconnect electric connector. Do not disconnect hydraulic lines. Tie clutch booster onto frame.

AR25.20-T-0300AA

 Installation: Introduce pressure plunger into clutch booster.

17

Take off attached parts and electrical plug connections at transmission

18

Separate plug connection of engine wiring harness from engine

19

Detach electric cables of alternator wiring harness at both alternators

 Remove cover with air intake for cooled air from alternators if necessary.

Detach alternator wiring harness from engine.

20

Detach electric cables of starter wiring harness at starter

 Remove starter wiring harness from engine and transmission.

21

Detach cable retainer of engine and vehicle wiring harness from transmission

 Tie up cable retainer at frame.

22

Disconnect electrical connections of water temperature sensor, oil temperature sensor and proportioning valve at retarder

23.1

Remove refrigerant compressor

 Only for code (HKA)

AR83.55-T-5300AA

23.2

Remove carrier for refrigerant compressor

 Only for code (HKA)

 Danger!

Danger of injury to eyes caused by steering oil emerging at high pressure. Danger of poisoning caused by swallowing steering oil

Unscrew end limit screws a maximum of 5 turns. Wear safety glasses.

AS46.00-Z-0001-01A

24

Drain hydraulic fluid of power steering

Collect hydraulic oil in a suitable vessel.



Check and correct power steering fluid level

AP46.00-T-4611A

25

Remove air intake hose upstream of turbocharger

AR09.10-T-8030AA

26

Remove intermediate piece from lower charge air pipe on left

AR09.41-T-1317-02AA

27

Detach charge air pipe from left top pressure hose connector

AR09.41-T-8681-01AA



*BA09.41-N-1002-01H

28

Remove coolant pipes at inlet and outlet connection of coolant pump

AR20.20-T-7450AA

29

Detach feed and return line from spacer bracket and from hydraulic pump for hydraulic fan drive

AR20.40-T-0002AA

30

Detach feed line for fuel heat exchanger from fuel heat exchanger

 The feed line for the fuel heat exchanger is marked in blue.

AR47.25-T-0006AA

31

Separate feed line for fuel pump at quick-connector to fuel pump

 The feed line for the fuel pump is marked in green.

AR47.25-T-0006AA

32

Separate feed line for engine housing at quick-connector of connection fitting of engine housing

The feed line for the engine housing is marked in yellow.

AR47.25-T-0006AA

33

Disconnect leak oil line for return line of engine housing at quick-connector

AR47.25-T-0006AA

34

Support engine and secure with suitable equipment jack to prevent it falling down and toppling

Engine support device, engine hoist
gotis://A_01_09.0

35

Detach cross strut below transmission from longitudinal members

36

Remove front engine mount

 Installation: Inspect engine mount for damage, install new part if necessary.

AR22.10-T-4330AA

37

Remove rear engine mount

 Installation: Inspect engine mount for damage, install new part if necessary.

AR22.10-T-1160AA

38

Carefully lower engine and run out to the rear

39

Install in the reverse order



Checking

40

Pour in coolant

41

Pour in engine oil



Engine oil and filter change

AP18.00-T-0101BB

42

Pour in hydraulic fluid of power steering



Check and correct power steering fluid level

AP46.00-T-4611A

Number

Designation

Engine
457.9

BA09.41-N-1002-01H

Bolt, charge air pipe to charge air manifold

Nm

60