AR01.10-T-2401B | Remove/install engine with transmission | 14.2.12 |
ENGINES 441.980 in MODEL 613.355
ENGINES 402.970, 446.938 in MODEL 613.455 /485
T01.10-0008-06
| Remove/install | ||
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. | |
1 | Disconnecting the battery | First disconnect the negative terminal. To do this, unlock and pull out the battery tray. | |
2 | Open liftgate | ||
3 | Remove engine compartment flap | ||
4 | Remove floor plate above transmission from inside of vehicle | ||
5 | Remove rear bumper | ||
6 | Remove rear crossmember | ||
7 | Raise vehicle | ||
8 | Detach lower engine compartment paneling | ||
9 | Detach cross strut below transmission from underbody | ||
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. | |
10 | Drain coolant | ||
| Notes on coolant | All engines | |
| Drain/fill in coolant | ||
11 | Drain oil from power steering | ||
12 | Drain engine oil | ||
| Engine oil and filter change | ||
13 | Disconnect return line on steering gear | - Open front flap - Fold down center part of bumper - Pull out spare tire. Catch escaping steering gear oil in a clean vessel. | |
14 | Remove poly-V belt | ||
15 | Remove V-belt for air conditioning refrigerant compressor | ||
Danger! | Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
16 | Disconnect hose and line connections | ||
17 | Detach propeller shaft from rear axle | | |
18 | Detach shift rod from transmission | All except transmission 714.691 with EPS | |
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19 | Detach compressed-air lines from shift cylinders on transmission | Transmission 714.691 with EPS | |
20 | Unplug connectors from sensors from shift cylinders on transmission | Transmission 714.691 with EPS | |
21 | Disconnect backup light switch plug, speedometer plug and starter lockout switch plug from transmission | ||
22 | Remove clutch booster | Do not remove lines from clutch booster. | |
23 | Detach electrical connections on alternator | ||
24 | Detach electrical connections on starter | ||
25 | Detach electrical connections on retarder | Transmission 714.100 with Voith retarder | |
Electrical connections for retarder: - Water temperature sensor connector - Oil temperature sensor connector - Proportioning valve connector | |||
26 | Remove reservoir compressed air line from proportioning valve for retarder | Transmission 714.100 with Voith retarder | |
Depressurize system beforehand. | |||
27 | Remove positive and negative cable on substructure | ||
28 | Unhook accelerator linkage | ||
29 | Demount engine brake flap fitting from right turbocharger | Engine 402.970, 446.938 (V8-engines) | |
In this way the exhaust system is separated from engine. | |||
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30 | Disconnect exhaust flexible pipe from left turbocharger | Engine 402.970, 446.938 (V8-engines) | |
In this way the exhaust system is separated from engine. | |||
31 | Disconnect exhaust flexible pipe from turbocharger | Engine 441.980 (V6 engine) | |
In this way the exhaust system is separated from engine. | |||
32 | Remove engine with removal fixture | ||
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Engine support device, engine hoist | |||
33 | Install in the reverse order | ||
34 | Pour in engine oil | ||
| Engine oil and filter change | ||
35 | Pour in coolant | ||
| Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to correct concentration | ||
36 | Pour in oil for the power steering | ||
| Check and correct power steering fluid level |
Turbocharger
Number | Designation | Engine 402.970 | Engine 441.980 | Engine 446.938 | |
BA09.40-N-1001-01H | Screw/bolt, engine brake flap fitting to turbocharger | Nm | 50 | 50 | 50 |
Engine mounts, engine supports
Number | Designation | Engine 402.970/ | Engine | Engine 441.980 | ||
BA22.10-N-1001-01E | Screw/bolt, engine mount supporting bracket to side member | M12x1.5 | Nm | 70 | 70 | 70 |
Shift mechanism
Number | Designation | Trans-mission 714.100 | Trans-mission 714.668 | Trans-mission 714.690 | |
BA26.60-N-1004-01E | Screw/bolt, shift rod to transmission | Nm | 24 | 24 | 24 |
Propeller shaft
Number | Designation | Model 613.355/455/485 | |
BA41.10-N-1002-01E | Screw/bolt, propeller shaft to rear axle | Nm | 110 |
Torque wrench
000 589 64 21 00