Remove/install engine

AR01.10-I-2400C

Remove/install engine

14.2.12

 

Remove/install

 Installation

Replace self-locking nuts and bolts.

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 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

 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 by a maximum of
5 turns. Wear safety glasses.

AS46.00-Z-0001-01A

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.
Only pour fuels into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

1

Drain coolant



Replace coolant

AP20.00-I-2080B



Notes on coolant

AH20.00-N-2080-01A

 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

2

Disconnect battery



Notes on battery

AH54.10-P-0001-01A

3

Remove front bumper

4

Remove front flap

5

Remove lower crossmember (A)

6

Remove upper crossmember (B)

7

Remove charge air pipe

From charge air cooler to charge air manifold.

AR09.41-I-1311C

From turbocharger to charge air cooler

AR09.41-I-1311B

8

Remove radiator

AR20.20-I-3865B

9

Disconnect compressed-air line (21) from engine brake cylinder

10

Detach exhaust pipe (16) from engine brake valve connection

 Installation: Clean sealing surfaces.

11

Detach exhaust pipe (16) from transmission and fasten to frame

12

Disconnect air intake hose (18) from air filter housing

13

Disconnect electrical lines (22, 23) at starter
(M1)

14

Disconnect electric wiring harness (19) at alternator (G1) and at bracket

 Installation: Observe colored marks for electrical lines and the connecting points on the alternator (G1).

15

Disconnect ground cable (20) and electrical wiring harness at timing case

16

Release connector plug (4) on MR/PLD control unit and detach

17

Remove compressed air line (2) from fitting on compressor

 Inspect compressed-air line (2) for carbon deposits. In case of carbonization: 

Check all compressed air lines between compressor, compressed air drier and 4-circuit protection valve for carbonization. Replace parts showing carbon deposits.

18

Unscrew fuel feed line (5) on fuel filter

 Place match marks on fuel feed line (5) and connecting parts on fuel filter . Collect escaping fuel.

19

Unscrew fuel return line (6) on fuel filter

 Place match marks on fuel return line (6) and connecting parts on fuel filter . Collect escaping fuel.

20

Remove poly-V belt

Only on models fitted with air conditioning

AR13.22-I-1202B

21

Detach refrigerant compressor (9) at engine

Only on models fitted with air conditioning

 Do not remove refrigerant lines on refrigerant compressor (9).

22

Remove steering oil suction line (7) from steering oil suction line to power steering pump

 Collect escaping steering oil.

23

Remove steering oil pressure line (8) from steering oil pressure line to power steering pump

 Collect escaping steering oil.

24

Support transmission

 Use a main assembly jack and a suitable piece of wood to shim.

25

Remove transmission from timing case



*BA26.10-N-1001-01I

26

Remove gearshift linkage (1) from gearshift lever

 Do not remove gearshift linkage (1) on transmission.

27

Secure engine with assembly device (32) and secure a lifting truck against dropping



Device for remove/install of engine

WF58.50-I-0110-03B

28

Remove left engine support and right engine support

AR22.10-I-1200C

29

Pull out engine to the front.

30

Install in the reverse order

31

Reach in all transponder keys

 Only for installation of a reconditioned engine with a new MR/PLD control unit.

AR80.57-I-0010A

32

Check engine oil level, correct as indicated



Specified engine oils (service) - overview

Sheet 223.2

BB00.40-P-0223-02A

33

Start engine and check oil pressure indicator for idle speed

 Oil pressure must be indicated after a few seconds. Do not rev up engine as long as no oil pressure is indicated.

*BE18.00-N-1001-01C

34

Stop engine and check engine oil level after a waiting time of at least 5 minutes; correct if necessary

 The waiting time must be maintained.



Specified engine oils (service) - overview

Sheet 223.2

BB00.40-P-0223-02A

35

Bleed steering system

AR46.25-I-3300B

Number

Designation

Engine
900.9, 902.9, 904.9, 906.9

BE18.00-N-1001-01C

Engine oil pressure at

Idling speed

bar

0.5

maximum speed

bar

2.5

Number

Designation

Trans-mission
712.353

BA26.10-N-1001-01I

Bolt, transmission to flywheel housing

Nm

45