Remove/install engine with front axle carrier

AR01.10-L-2500VA

Remove/install engine with front axle carrier

10.11.11

22.1.02

Value changed from 15 Nm to 8 Nm

Value in series BA15.30-P-1003-01D for engine 668.914 modified

22.1.02

Value changed from 120 Nm to 110 Nm

Value in series BA33.10-P-1001-01B for model 414.600/700
modified

 

Remove/install

 Danger!

Risk of death caused by vehicle slipping or toppling off of the lifting platform.

Align vehicle between columns of lifting platform and position the four support plates at lifting platform support points specified by vehicle manufacturer.

AS00.00-Z-0010-01A



Notes on self-locking nuts and bolts

All models

AH00.00-N-0001-01A

1

Remove front wheels



AP40.10-P-4050Z

2

Disconnect battery ground line

AR54.10-P-0003A

3

Remove bottom section of soundproofing

 Remove only engine compartment paneling at front, engine compartment paneling at front right and engine compartment paneling at front left.

AR94.30-L-5300VA

4.1

Unscrew oil drain screw from oil pan at automatic transmission and drain ATF

 On models fitted with automatic transmission.



*BA27.10-P-1001-03A

5

Drain coolant

 At radiator and at crankcase.

AR20.00-L-1142VA

6

Remove front bumper.

AR88.20-L-2000VA

7

Separate plug connection (47) at outside temperature display temperature sensor (B14)

 Ensure plug connection (47) is correctly seated.

8

Remove charge air cooler

AR09.41-P-6817GD

9

Remove washer fluid reservoir

 Twist locking lever and lift washer fluid reservoir.

Use a screwdriver to press the washer fluid pump off the washer fluid reservoir with lines connected.

10

Disconnect engine wiring harness

AR15.18-L-1000-02VA

11

Detach air intake scoop (1) and air intake duct (2) from front end cross member

Hose clamps which have been opened, must be inspected for visible damage and replaced, if necessary

12

Detach vacuum line (3) at turbocharger and unclip at air intake pipe (20)

13

Detach vacuum line (9) at mixing chamber

14

Detach vacuum line (4) at charge pressure sensor at firewall

15

Take off vacuum line (5) at vacuum pump and unclip at intake module

 Quick-release fitting

Press together catches (arrows) and detach vacuum line (5).

16

Remove induction hose from turbocharger (12) from plenum chamber

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

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

17

Detach fuel lines (6 and 7) at fuel full-flow filter and seal with suitable plugs



*129589009100

18

Take off coolant hose (10) from connection piece (19)

19

Detach coolant hose (11) at coolant thermostat

20

Detach coolant hose (8) at firewall

21

Detach coolant hose (15) at top of radiator and detach coolant hose (17) at coolant expansion reservoir (16)

22

Detach coolant hose (14) at bottom of radiator (18) and unclip along side of longitudinal member (arrow)

23.1

Detach ATF lines (13) at oil cooler and seal with suitable plug

 On models fitted with automatic transmission.

The oil cooler is integrated within the radiator.



*BA20.20-P-1002-01G



*129589009100

24

Turn steering wheel into middle position, withdraw ignition key and engage steering lock

25

Remove screw/bolt (35) and detach steering coupling (32) at the steering shaft (33), take off thrust piece (34)

 Installation: Install new nut holder (36).



*BA46.10-P-1002-01C

26

Disconnect ground cable from left front engine support

27

Disconnect positive cable (31) and control cable (30) for power steering pump at left frame longitudinal member

28.1

Turn clamping nuts (arrows) in anti-clockwise direction. Detach gear selection shift cable (28) and gate selection shift cable (29) from the bracket

 On models fitted with manual transmission.

29.1

Unclip gear selection shift cable (28) and gate selection shift cable (29) from the ball head

 On models fitted with manual transmission.

Installation: Gear selection shift cable (28) and gate selection shift cable (29) have to be properly locked in the ball head.

30.1

Separate plug connection (58) to backup lamp switch (S16/2)

 On models fitted with manual transmission.

Installation: Pay attention to the correct position of the connector (58).

31.1

Unplug connectors from selection direction turning angle sensor (B54/1) and shift direction turning angle sensor (B54).

 On models fitted with automatic clutch actuation (code GS5).

Installation: Pay attention to the correct position of the connector.

32.1

Detach wiring harness of turning angle sensors (B54 and B54/1) at the manual transmission, and expose

 Replace cable ties.

33.1

Unscrew screw/bolt (25) from bracket (24)

 On models fitted with automatic transmission.



*BA27.10-P-1002-04B

34

Remove screw/bolts (44) and detach suspension strut (43) at strut dome

 Installation: Insert the guide pins (arrows) in the spring tower.



*BA32.25-P-1002-04A

35

Unscrew screw/bolts (41).

Detach floating caliper (40) at steering knuckle and tie up in wheel well together with brake pads, and with brake hose connected

 Installation: Replace screw/bolts (41).



*BA42.10-P-1001-03B

36

Unclip brake pads contact sensor (S10/2) and cable of left front axle wheel speed sensor (L6/1), cable of right front axle wheel speed sensor (L6/2) at suspension strut (43), and expose cables

 Brake bad contact sensor (S10/2) is installed only at front right.

37

Unscrew screw/bolts (45) and remove cover (46) on left and right at front axle carrier (37)

 Danger!

Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes.

Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid.

AS42.50-Z-0001-01A



Brake fluid notes

All models

AH42.50-P-0001-01A

38

Remove locking element (27) and pull clutch line (26) out of transmission

 Seal clutch line (26) with a suitable plug.

Installation: Replace fuse (27) and sealing ring.



*129589009100

39

Take off clamp (52) together with assembly lever and separate exhaust system at connection point

 Inspect retaining clamp (52), replace if necessary.

 Installation: Open side of the retaining clamp (52) points downwards.

40

Unscrew screw/bolts (55). Detach wiring harness together with bracket (56) and ground cable (57) at oil pan

41.1

Release the poly-V belt (50) and remove it from refrigerant compressor (A9)

 Vehicles with air conditioning.

(code H06).

AR13.22-P-1202GF

42

Remove fender liners from underfloor on left and right sides and fold down

 To gain access to the rear screw/bolts (42).

43.1

Detach bracket for AC line at rear right of front axle carrier (37)

 On models fitted with air conditioning (code H06).

44.1

Remove screw/bolts attaching refrigerant compressor (A9). Take off refrigerant compressor (A9) and attach to underfloor with cables and refrigerant lines connected

 Do not separate refrigerant hoses.

 Vehicles with air conditioning.

(code H06).

45

Unscrew screw/bolts (38). Take off strut (39) on left and right at front axle carrier (37) and at underfloor



*BA33.10-P-1003-01B

46

Position removal fixture of front axle carrier (51) at front axle carrier (37)

Jack assembly adapter

gotis://A_25/35/49_03.0

47

Turn out screw/bolts (42) on both sides

 Installation: First fit all the screw/bolts (42), then tighten.



*BA33.10-P-1001-01B

48

Carefully lower engine together with front axle carrier (37) far enough to gain access to starter (M1) and alternator (G2)

 Proceed with caution to avoid damaging coolant hoses, AC hoses and electrical wiring.

Installation: Guides (arrow) on the front-axle carrier (37) must be inserted into the holes in the longitudinal member.

Guides of the suspension struts (43) must be inserted into the holes in the suspension strut dome (arrows).

49.1

Detach selector range cable (23) at the shift linkage

 On models fitted with automatic transmission.

50.1

Pull bracket (24) at automatic transmission out of the mount (arrow).

 On models fitted with automatic transmission.

51.1

Separate electrical plug connection (22) at transmission and expose cable

 On models fitted with automatic clutch actuation (code GS5) or on models fitted with automatic transmission.

52

Detach wiring harness (48) at starter (M1)

 Terminal 50

*BA15.30-P-1002-01D

 Terminal 30

*BA15.30-P-1003-01D

53

Detach wiring harness (49) at alternator (G2)

 Ensure plug connection is correctly seated.

*BA15.40-P-1001-01C

 Circuit B+

*BA15.40-P-1002-01C

54

Carefully lower engine with front axle carrier (37) fully

 Proceed with caution to avoid damaging coolant hoses, a/c hoses and electrical wiring.

55

Install in the reverse order

 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.
Always wear appropriate work clothing when working on the vehicle.

AS00.00-Z-0005-01A

56

Check for leaks with engine running

57

Inspect ATF level in transmission, pour in ATF if necessary

 On models fitted with automatic transmission.

AR27.00-P-0101GC

58

Bleed clutch operating system

AR25.20-L-0070VA

59

Inspect cooling system for leaks

AR20.00-L-1010VA

60

Read out fault memory



Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000-04A

STAR DIAGNOSIS diagnosis system

Number

Designation

Engine
668.914

BA15.30-P-1002-01D

Cable to starter circuit 50

Nm

6

BA15.30-P-1003-01D

Cable on starter circuit 30

Nm

8

Number

Designation

Engine 668

BA15.40-P-1001-01C

Cable on alternator terminal D+

Nm

6

BA15.40-P-1002-01C

Cable on alternator terminal B+

Nm

18

Number

Designation

Engine 668.914

BA20.20-P-1002-01G

Union nut, automatic transmission oil line to radiator

Nm

25

Number

Designation

Transmission 722.750/751
in model 414

BA27.10-P-1002-04B

Screw/bolt, range selector cable bracket to transmission

Nm

8

Number

Designation

Trans-mission 722.3

Trans-mission 722.4/5/7

BA27.10-P-1001-03A

Drain plug on transmission oil pan

Nm

14

22

Number

Designation

Model 414

BA32.25-P-1002-04A

Screw/bolt, suspension strut to suspension strut dome

Nm

40

Number

Designation

Model
414.700

BA33.10-P-1001-01B

Screw/bolt, front-axle carrier to body

M 12

Nm

110

BA33.10-P-1003-01B

Strut bolt on front-axle carrier
and body

M 10

Nm

50

Number

Designation

Model 414

BA42.10-P-1001-03B

Self-locking nut, floating caliper to steering knuckle

Nm

115

Number

Designation

Model 414

BA46.10-P-1002-01C

Screw/bolt, steering coupling to steering shaft

Nm

20