Remove/install engine - AR01.10-P-2400HC
ENGINE 606.962 in MODEL 210
| Remove/install | |||
| 1 | Disconnect battery ground cable | AR54.10-P-0003A | |
| 2 | Remove aspirator hose (1) | ||
| 3 | Remove air filter housing (2). | ||
| 4 | Remove bottom section of sound-proofing capsule | Model 210 | AR94.30-P-5300AB |
| Risk of injury
to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning from 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 | AR20.00-P-1142HW | |
| 6 | Disconnect automatic transmission oil lines | Connection fitting for automatic transmission oil lines | |
| Connect transmission oil lines with a plug | WF58.50-P-2020-01A | ||
| 7 | Remove radiator | AR20.20-P-3865HB | |
| 8 | Disconnect coolant hose (4) at cylinder head and coolant hose (3) at oil filter housing | ||
| *WH58.30-Z-1001-06A | |||
| *WH58.30-Z-1002-06A | |||
| 9 | Attach guard plate for radiator / condenser | if AC (code 580, 581) fitted | |
| Guard plate for radiator / condenser | WF58.50-P-0110-01A | ||
| 10 | Disconnect engine wiring harness | AR01.00-P-2410H | |
| 11 | Unscrew exhaust system (5) at intermediate flange of turbocharger and at transmission | ||
| 12 | Remove boost pressure hoses (6, 7). | ||
| 13.1 | Remove poly-V-belt | if AC (code 580, 581) fitted | AR13.22-P-1202HA |
| 14 | Disconnect lines of vacuum supply (8, 9, 10, 11) | Identify lines if necessary Engine 606 Diagnosis Manual diesel engine volume 1 Register 3.1 |
|
| 15 | Unscrew lines of power steering pump (12, 13) | Before disconnecting the lines, extract oil at reservoir. |
AR46.30-P-0500A |
| *BA46.30-P-1002-01A | |||
| *BA46.30-P-1003-01A | |||
| *112589007200 | |||
| 16 | Separate lines of engine oil cooler (14 | ||
| 17.1 | Unplug electrical connection of AC compressor | if AC (code 580, 581) fitted | |
| 18.1 | Unbolt AC compressor (15) | if AC (code 580, 581) fitted |
*BA83.55-P-1001-01A |
| 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 | |
| 19 | Disconnect fuel lines (16, 17) | ||
| 20 | Unhinge shift rod at selector lever | ||
| 21 | Unscrew propeller shaft at transmission | AR41.10-P-0050EA | |
| 22 | Remove/install cable for parking shift lock (18) | AR27.60-P-1000B | |
| Adjust cable for parking shift lock | AR27.60-P-0965B | ||
| 23 | Remove right protective shield (20) at transmission | ||
| 24 | Disconnect connector (19) for electrical control unit at the transmission | ||
| 25 | Unbolt engine mounts at front body. | AR22.10-P-1260HA | |
| 26 | Remove rear engine mount | AR22.10-P-1160HB | |
| 27 | Raise engine, remove | AR01.10-P-7500-03HA | |
| *WE58.40-Z-1012-11A | |||
| *WH58.30-Z-1001-07A | |||
| 28 | Install in the reverse order | ||
| 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 engine | Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts. |
AS00.00-Z-0005-01A | |
| 29 | Inspect ATF level in automatic transmission | AR27.00-P-0101A | |
| 30 | Inspect oil level of power steering pump, adjust to correct level | AP46.00-P-4611BB | |
| 31.1 | Fill pressure oil system | If level control (code 217B) fitted | AR32.30-P-0630A |
| 32 | Fill cooling system | AR20.00-P-1142HA | |
| Notes on coolant | All engines | AH20.00-N-2080-01A | |
| 33 | Inspect cooling system for leaks | Do not pressure-test cooling system until engine has reached operating temperature. |
AR20.00-P-1010HA |
| 34 | Read fault memory, erase. | Stored faults possibly caused by previous simulation or by cables disconnected in the process of installation or testing must be processed and erased in the DTC memories once all work is completed. Diagnosis Manual Volume 1.1: Index 0: Connecting and using test equipment. |
| Number | Designation | Engines 104.945/995, 111.942/947/970, 604.912/917, 605.912/962, 606.912/962 in model 210 | |
|---|---|---|---|
| BA83.55-P-1001-01A | Bolt, refrigerant compressor to bracket | Nm | 23 |
| Number | Designation | Model 210.003/004/010/ 015/017/020/025/035/ 037/045/053/055/072/ 210/215/217/225/235/ 237/245/272/610/617 | Models 210.061/063/ 065/070/074/08 1/082/083/261/ 263/265/270/274/281/282/283/ 663 | ||
|---|---|---|---|---|---|
| BA46.30-P-1002-01A | Return line to power steering pump | Nm | - | 2 | |
| BA46.30-P-1003-01A | High-pressure expansion hose to power steering pump | M14x1.5 | Nm | - | - |
| M16x1.5 | Nm | 45 | 45 | ||
Commercially available tools
| Number | Designation |
|---|---|
| WH58.30-Z-1001-06A | 6 mm socket hexagon on flexible shaft for hose clamps with worm drive |
| WH58.30-Z-1002-06A | 7 mm socket hexagon on flexible shaft for hose clamps with worm drive |
| WH58.30-Z-1001-07A | Shackle, DIN 82101 |
Workshop equipment
| WE58.40-Z-1012-11A | Load regulator (engine hoist), self-locking |