Remove/install axle/engine subframe with engine

AR31.35-S-4200A

Remove/install axle/engine subframe with engine

10.11.11

 

Remove/install

1.1

Put vehicle into service mode.

 With code CL0 (air suspension).

2

Raise vehicle



Special instructions for lifting and supporting vehicle

Model 638

AH00.60-N-0100-01A

3

Disconnect ground line of battery

AR54.10-S-0005A



Notes on battery

All models

AH54.10-P-0001-01A

4

Remove bottom section of soundproofing

AR94.30-S-5300A

 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

5

Drain coolant at radiator

AP20.00-D-2080A

6.1

Drain air conditioning system

 With code H06 (A/C).

AR83.30-S-1760A

7

Remove front bumper.

AR88.20-S-2000A

8

Remove grill (1)

AR88.00-S-2115A

9

Remove lock crossmember (5)

AR88.00-S-2302A

10

Remove air filter housing (6).

AR09.10-S-1150A

11

Remove headlamp with right front turn signal (4)

AR82.10-S-4720A

12

Disconnect engine wiring harness

AR01.00-S-2410A

13

Disconnect connectors on radiator

14

Detach coolant hose (7) from coolant pump (8)

 Check coolant hose (7) and hose clamp for condition, replace if necessary.

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

15

Unhook accelerator pedal cable (9) from bracket

AR30.10-S-3070-02A

16

Pull vacuum line (15) off idle speed control actuator (M33)

17

Pull vacuum lines (11) off intake manifold

18

Unscrew vacuum line (10) at intake manifold



*BA09.20-N-1004-02A

19

Detach coolant hose (12) from fitting (14) of cylinder head

 Check coolant hose (12) and clamp (13) for condition, replace if necessary

7 mm socket hexagon on flexible shaft for hose clamps with worm drive

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

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

20

Unlock and disconnect fuel lines (21, 22)

 Collect escaping fuel.

21

Unscrew bolt (18) from bracket (19).

22.1

Unscrew refrigerant lines (16) on expansion valve

 With code H06 (A/C).

 Replace sealing rings (20).



*BA83.30-N-1001-01A

23.1

Detach shift cables from transmission.

 Without code G40 (automatic transmission)

AR26.60-S-6627-01A

23.2

Unhook shift cable from automatic transmission

 With code G40 (AT).

AR27.60-S-0100-01A

24

Remove front road wheels (27).

AR40.10-S-1100A

25

Remove heater air inlet

AR83.25-S-1401A

26

Unscrew threaded connection on suspension strut (62)

Use a box-end wrench to apply counterpressure to the shock absorber insert to prevent it from twisting when the nut is being loosened and tightened.



*BA32.25-N-1002-04A

27

Remove brake caliper (35)

 In order to avoid damage, do not stretch brake hoses.

AR42.10-S-0600A

 Attach brake caliper (35) to body using a suitable wire bracket.

28.1

Detach ABS sensors (B79) with shield (29) on left and right steering knuckle

 With code BB0 (ABS/ABD or ABS/ETS).

AR42.30-S-0150A

 Do not disconnect electrical connection.

29

Remove bearing cup (42) and shackle (40) in left and right wheel arch

 Installation: Replace self-locking bolts (41, 43). Install fish-plates (40) on correct sides. Observe installation position of fish-plates (40).



*BA31.35-N-1003-01A



*BA31.35-N-1004-01A

30

Disconnect connector (X106)

 With code G40 (AT).

31.1

Disconnect connector on backup light switch (S19)

 Without code G40 (AT).

32.1

Detach clutch slave cylinder (44) at transmission

 Without code G40 (AT).

AR25.20-S-0150A

 Do not disconnect hydraulic line.

33.1

Do not detach speedometer sensor (G4) or tachograph from transmission

 Do not disconnect electrical connection.

AR54.75-S-5360A

34

Mark position of shaft of steering gear (48) and universal joint (47) with a suitable colored pencil (arrow)

 Installation: Align color coding (arrow) of steering gear shaft (48) and universal joint (47). Center steering position is retained.

35

Unscrew screw/bolt (46)

 Installation: Insert universal joint (47) in the steering gear shaft (48) until the bore in the universal joint (47) aligns with the radial groove in the steering gear shaft (48). Replace bolt (46)



*BA46.10-N-1003-05A

 Torx bit set

*000589011000

36

Unscrew ground line on frame floor assembly



Assembly notes for exhaust systems with corrugated hose

Engine 111, 601 in model 638

AH49.10-N-0200-01A

37

Remove exhaust system (51) at exhaust manifold (52)

 Installation: Assemble flange connection so that it aligns.

AR49.10-S-7140-01A



*BA49.10-N-1001-01A

38

Mount removal fixture (61) on axle/engine subframe (60)

 In order to avoid the engine falling down, align all the support points. Secure axle/engine subframe (60) with major assemblies at the removal fixture (61) using a suitable tensioning strap.

Lifter mounting adapter
gotis://A_25/35/49_03.0

39

Remove front stop elements (55)

 Observe installation position.



*BA31.35-N-1002-01A

40

Lay engine wiring harness, vacuum lines, coolant hoses, cables and disassembled vehicle parts to one side, bind up together if necessary

 Unobstructed outwards movement of the axle/engine subframe (60) must be guaranteed, do not damage components!.

41

Unscrew bolts (56, 58)



*BA31.35-N-1001-01A

42

Lower engine with axle/engine subframe (60) downwards slowly

 In order to avoid damage to the steering, guarantee the extraction or insertion of the shaft of the steering gear (48) from the universal joint (47) by rotary motion of the steering shaft!
Ensure that adequate clearance to the exhaust system and removed vehicle parts is available!
 Installation: Align axle/engine subframe (60) so that the bolts (56, 58) can be installed and the insertion of the shaft of the steering gear (48) in the universal joint (47) is guaranteed.

43

Install in the reverse order



Checking

44

Check for leaks, ensure that all fluids are at prescribed levels.

Number

Designation

Engine 111.948/
978

BA09.20-N-1004-02A

Vacuum line to vacuum connection of intake manifold

Nm

30

Number

Designation

Model
638.014/034/
064/074/094/
114/134/164/ 174/194/214/ 234/244/274/294
without code G40

Model
638.014/034/
064/074/094/
114/134/164/ 174/194/214/ 234/244/274/294
with code G40

BA31.35-N-1001-01A

Axle/engine subframe on main vehicle frame

Nm

150

150

BA31.35-N-1002-01A

Front travel stop on frame

Nm

105

105

BA31.35-N-1003-01A

Bearing dish in fish-plate on frame

Nm

72

72

BA31.35-N-1004-01A

Bearing dish on front subframe

Nm

172

172

Number

Designation

Model
638

BA32.25-N-1002-04A

Nut, strut to body

Nm

66

Number

Designation

Steering 763.000 in model 638

Steering 763.000 in model series 638 with airbag

BA46.10-N-1003-05A

Universal joint to steering gear shaft
(TORX bolt)

Nm

24

24

Number

Designation

Engine 111.948/
978

BA49.10-N-1001-01A

Flange connection for front exhaust system - exhaust manifold

Nm

28

Number

Designation

Model
638

BA83.30-N-1001-01A

Nut, suction and high pressure line to expansion valve

Nm

10